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Intercooler analysis

waldig
October 28, 2012
 28
 0
Guts of the beast Read more ยป
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relay wiring
relay wiring
0 2012/12/22 08:03:38 waldig
IC test bed
IC test bed
0 2012/12/19 18:09:57 waldig
90 series pump
90 series pump
0 2012/11/25 16:52:13 waldig
Location of casting fault
Location of casting fault
0 2012/11/16 13:21:27 waldig
Sectioned IC for testing of pressure capacity of water side.  Will be used for testing of single pass water restriction in a real SRT.
Sectioned IC for testing of pressure capacity of water side. Will be used for testing of single pass water restriction in a real SRT.
0 2012/11/16 13:21:27 waldig
Leak at corner
Leak at corner
0 2012/11/16 13:21:27 waldig
Leak found at the factory weld line of case
Leak found at the factory weld line of case
0 2012/11/16 13:21:27 waldig
vacuuming heat out of welded core after reassembly..
vacuuming heat out of welded core after reassembly..
0 2012/11/12 14:12:12 waldig
Washed 4 times, soap n water, chemical cleaner, lacquer thinner twice, acetone rinsed.
Washed 4 times, soap n water, chemical cleaner, lacquer thinner twice, acetone rinsed.
0 2012/11/12 14:12:12 waldig
washed core  shiny fins
washed core shiny fins
0 2012/11/12 14:12:12 waldig
IC inlet dirty
IC inlet dirty
0 2012/11/03 10:50:23 waldig
rewelding cleaned case back together
rewelding cleaned case back together
0 2012/11/03 10:25:03 waldig
washed core
washed core
0 2012/11/03 10:25:03 waldig
IC opening 3
IC opening 3
0 2012/11/03 10:25:03 waldig
dirty outlet section seen from IC's point of view
dirty outlet section seen from IC's point of view
0 2012/11/03 10:22:17 waldig
IC sawn open 2
IC sawn open 2
0 2012/11/03 10:22:17 waldig
IC as received 2
IC as received 2
0 2012/11/03 10:22:17 waldig
Another view of the heat exchanger pipes in the I/C - brutal mess...
Another view of the heat exchanger pipes in the I/C - brutal mess...
0 2012/10/29 10:34:51 waldig
Open kimona of a heat exchanger, the I/C.  Take a look see.
Open kimona of a heat exchanger, the I/C. Take a look see.
0 2012/10/29 10:34:51 waldig
NASTY, this is in our cars, but I have a plan and will test a fix.
NASTY, this is in our cars, but I have a plan and will test a fix.
0 2012/10/29 10:34:51 waldig
More ugly rework at the factory.  DO NOT become concerned with the closed ports, the cutting process left flashings on the ends of the tubes where the blades hit the tubing, they were all open, cutting did the mushing of the ends, flashing picks off easily. Woody
More ugly rework at the factory. DO NOT become concerned with the closed ports, the cutting process left flashings on the ends of the tubes where the blades hit the tubing, they were all open, cutting did the mushing of the ends, flashing picks off easily. Woody
0 2012/10/29 10:31:13 waldig
Note the cold water enters the top right and exits on the bottom left pipe.
Note the cold water enters the top right and exits on the bottom left pipe.
0 2012/10/29 10:31:13 waldig
Please note the flow of water in the intercooler, it is serial on three passes or loops thru the air path
Please note the flow of water in the intercooler, it is serial on three passes or loops thru the air path
0 2012/10/29 10:31:13 waldig
Sample I/C ready for analysis - cutup.
Sample I/C ready for analysis - cutup.
0 2012/10/28 18:15:04 waldig
Outlet contamination due to leak in core.
Outlet contamination due to leak in core.
0 2012/10/28 18:15:04 waldig
Inlet view of I/C
Inlet view of I/C
0 2012/10/28 18:15:04 waldig
Opening the intercooler
Opening the intercooler
0 2012/10/28 12:16:15 waldig
Rework done at the factory
Rework done at the factory
0 2012/10/28 12:16:15 waldig

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