Haha, yes the air at one bar is sooo much thicker . Dirt or no dirt, there won't be any measurable horsepower loss due to it as.. the placement of the IC > any flow restriction

 

i got stuck trying to find a suitable gauge to use to test with, ill get a small mechanical one today to get this done

 

I have a leaking IC - hoping for a permanent solution. I have pursued several options but none of them have panned out.

 

I think that Waldig and Rob could come up with something here.

 

This is some great info... keep up the great works guys. Following intently

 

Hear hear! I agree with goodgenes79......I will be keeping an eye on this very intently!

 

I hope this is the start of Needswings "Tweaked Charge Air Coolers". Go Rob and Woody. Steve(32Krazy)mentioned adding (2)inlets @ the opposite end for increased flow. Is there merit in pursuing that as part of the Mod? Good luck w/ a solution to the poorly built Mexican cores.

 

I'm not sure if it's too late for Woody's unit, but one simple (but slightly time consuming) mod if you have the cooler out for a clean would be to dremmel burnish the inlets and outlets of each of the little capillaries so that they arent a flat sharp entrance, but rather a rounded face facing the incoming/outgoing air - we call this in the business the "kv loss factor" and has a marked improvement on entrance and discharge losses.

It wont improve cooling but it will reduce dP (pressure drop) a little.
Post Script - after analysis resulting in the later post - this will only hlep water dP, not air dP

 

For those of us with a little lack of conceptualisation......
Without pulling my own apart, I felt a need to understand the construction of the unit before doing some calcs and possibly helping (where I can) with the derivation of a new concept design - if we ever get that far.

Wood - hoping you may be able to scratch out some dimensions - namely the;
FINS - thickness, height(amplitude), spacing (pitch), and total width across the cooler - guess 0.3mm, 10mm, 8mm, 80mm????
Channels - inside dimensions (width,height), wall thickness, number of channels, centre to centre between rows - guess (2.5x4mm), 1mm, 25????, 12mm
Another interesting unit would be the approximate mass of metal (aluminium) composing just the cooler element itself.....guess...2lbs?
Keeping in mind you gotta heat that up as well as your water.

 

Rob has looked at some core material, and may be able to get you some dimensions, I did not even look at the size.

Iam trying to see how hard it is to repair the IC, and how well this can be done. When I get it fixed, I will test it probably to failure to see how much safety factor I can build into the ''mexican'' units, which most of us have in our cars.

Just like the differential failures, I see the IC issue as a loomimg problem for the group. In the mean time, Ill see if I can get comfortable with the IC.

NEED: I am still looking to get another bad IC, and I wish to get a photo of the IC sitting on the engine for spacing issues. Can anyone assist me???? Hope so.

Enjoy, Woody


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Now wrap that puppy up and put her back in the cradle... and go really really fast....

 

You guys confuse me... How do you clean it, without pulling the engine or there abouts???

 

Good old fort story and story II.

You have to pull the supercharger to remove the IC. We are surmizing the methods to clean it in place. I have little belief that this is possible after doing the study of several failed units. Lacquer thinner, paint thinner, soap and water, agitation of the solution, and high pressure hot water are all limited in cleaning the IC; OUT OF THE CAR.

THe amount of gunk is amazing, I have filter papers from the solvent, with the sediment on it, its not all fluid there is a Composition of oil, DIRT, and grit on the core internal surfaces.

Woody

 

Mine came out clean! I used water/methanol spraying through the supercharger.

Les

 

Here's a link to my leaking intercooler.
https://www.crossfireforum.org/forum...tml#post713742

Les

 

Always good to have a guinea pig...great news...!
Inspected the PTFE coating on the SC rotors/screws post?

how did you determine it was "so clean" post....

just looked at the link..hmmmm