How big is your intercooler?

[eclipse_turbo97]

What are the dimensions on your FMIC? Getting ready to add one to the setup and want a BIG one. I looked at one that was 28"x12"x4". Is that too big? It had 3" in and outs on it also.

 

[Flash]

If you had updated you car profile we could better help you with the one you need. Update and post your mod list in your profile.

 

[snox135]

Also what are your goals for the car? If your planning on upgrading more in the future.

 

[95GSXBLUR]

Slow Boy Racing sells a 24x12x3.5" bar and plate core w/ nice aluminum endtakes that w/ 2.5" SHORT ROUTE piping. I use it on my car - it flows 1000cfm. More than enough for 600+ Horse power.

I highly recommend it. Welds and beaded pipes are awesome. If I'm not mistaken the core is made by PTE.

It's really HUGE. More than most would ever need.

 

[AuntiesTSI]

I have the DV/DT Fab FMIC, I can't remember the exact dimensions and the site is down apparently, but it's HUGE.

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[snox135]

Not only huge but the best end tank design out there

 

[AuntiesTSI]

Not only huge but the best end tank design out there

 

[Boosted98gsx]

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[eclipse_turbo97]

That one is huge haha... I updated my profile for the mods. Sorry I didn't give ya enough info on it.

 

[Elvenhome21]

be prepared to do a LOT of fab work and cutting. I have a 28x12x3 and it was a PITA to put in and get the piping routed nicely.

 

[turbo addict]

ninja, measure that thing I am interested how big that is.

Mine is a 24-12-4.5 with 3 in and out, but was made for a skyline so has very nice long gradual end tanks.(smooth transition)

 

[95GSXBLUR]

Pics of the Slowboy Core Installed and Right after I got it

<a href="http://photobucket.com" target="_blank"><img src="http://i156.photobucket.com/albums/t30/manicpunkrocker/TestfitFMIC.jpg" border="0" alt="Photo Sharing and Video Hosting at Photobucket"></a>

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<a href="http://photobucket.com" target="_blank"><img src="http://i156.photobucket.com/albums/t30/manicpunkrocker/FrontofIntercooler.jpg" border="0" alt="Photo Sharing and Video Hosting at Photobucket"></a>

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[Jeff822]

Dejon "new" kit

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[Low Impedance]

3" thick intercoolers are almost too thick, i couldnt even imagine trying to flow air through a 4.5" thick intercooler.

NOTE: bigger is not always better.

 

[Boosted98gsx]

Air in = Air out. And typically, it's the endtanks blocking airflow to the radiator that cause overheating problems, not the thickness of the core. As air goes through the fins, granted it will get warmer, but its velocity will increase in the process aiding its destination to the radiator.

 

[Low Impedance]

Air in = Air out. And typically, it's the endtanks blocking airflow to the radiator that cause overheating problems, not the thickness of the core. As air goes through the fins, granted it will get warmer, but its velocity will increase in the process aiding its destination to the radiator.

obviously air cant flow through solid aluminum. BUT air does not increase velocity through the fins. There is more drag created. It slows down making fresh air harder to get through to cool the charge, let alone the radiator. Additionally, gains made by the thickness are marginal. Roughly speaking, the first half of the core will do 75% of the cooling. The second half will do only 25%. Obviously this is truncating the values, but its makes the explainations simplier.

 

[blcknspo0ln]

obviously air cant flow through solid aluminum. BUT air does not increase velocity through the fins. There is more drag created. It slows down making fresh air harder to get through to cool the charge, let alone the radiator. Additionally, gains made by the thickness are marginal. Roughly speaking, the first half of the core will do 75% of the cooling. The second half will do only 25%. Obviously this is truncating the values, but its makes the explainations simplier.

Actually it's not the front half and back half that you should be comparing, but rather small sections of the core itself do the majority of the cooling.

That being said, I ran the SSAC 2g big FMIC kit from eBay, it's a hefty 33x10.5x3.5 or something of the like. For 300 bucks and no overheating/heatsoak issues, I can't complain

 

[GVR4592]

Here are some pics of the SBR intercooler. I just saw another one this weekend with the same problem, I'll try to get those pics in a couple days.

 

[Low Impedance]

Actually it's not the front half and back half that you should be comparing, but rather small sections of the core itself do the majority of the cooling.

That being said, I ran the SSAC 2g big FMIC kit from eBay, it's a hefty 33x10.5x3.5 or something of the like. For 300 bucks and no overheating/heatsoak issues, I can't complain

if we really wanted too we can look at this in a 3-D fashion. Odds are most of the cooling is going to happen roughly 1/3 of the way into the core from the inlet end tank, if we are talking resultants. (maximum temp loss should be just after the air enters the core, then it makes a gradiual slope down to the temp that is arrives at the outlet end tank). What sucks is that the cooling graph isnt linear so its kinda hard to calculate. At the same time, as i stated, the first 50% of the core thickness if doing 75% of the cooling. Here too its not linear. So you have two graphs of curves intersecting.

its getting late to be explaining heat transfer and fluid dynamics.

cliff notes: weld a few saab cores together.

 

[GVR4592]

if we really wanted too we can look at this in a 3-D fashion. Odds are most of the cooling is going to happen roughly 1/3 of the way into the core from the inlet end tank, if we are talking resultants. (maximum temp loss should be just after the air enters the core, then it makes a gradiual slope down to the temp that is arrives at the outlet end tank). What sucks is that the cooling graph isnt linear so its kinda hard to calculate. At the same time, as i stated, the first 50% of the core thickness if doing 75% of the cooling. Here too its not linear. So you have two graphs of curves intersecting.

its getting late to be explaining heat transfer and fluid dynamics.

cliff notes: weld a few saab cores together.

Sounds like that came straight from Maximum Boost(good book). Have you read this article?

http://www.are.com.au/feat/techtalk/intecoolersMR.htm

 

[Low Impedance]

i think that book should be required reading for any forum involving forced induction.

but my statement is a combination of information, including from some of my classes. Maybe if i get REALLY bored, ill do a study. I have enough intercoolers laying around to get a good comparison.

ill read the link you posted as well.

 

[AuntiesTSI]

ninja, measure that thing I am interested how big that is.

Mine is a 24-12-4.5 with 3 in and out, but was made for a skyline so has very nice long gradual end tanks.(smooth transition)

I should be able to get some measurements for you on Thursday, that's when I am going out to the shop next. Work owns me.

 

[DSM90AWD]

Here are some pics of the SBR intercooler. I just saw another one this weekend with the same problem, I'll try to get those pics in a couple days.

Not directed at you Luke, but many of the endtank failures I've seen have been the result of the kit/installer not allowing for enough "flex" in the piping to/from the core. Note that the engine will rock fore/aft with acceleration (especially with worn engine/tranny mounts) and the core is rigidly mounted to the car's frame. If you do not allow for some "flex" in the piping, then the endtanks will fatigue and the welds (the weakest points) will fail.

As such, I recommend that at least one "hump" style connector be used on the inlet and outlet run of the FMIC pipes to help isolate the core / intake manifold from these stresses.

As for core thickness, (to bring up Corky bell in yet another thread) he mentions that it is always best to have a tall but thin core. When you cannot get enough height, you can compromise internal volume by increasing depth, but by sacrificing efficiency as each subsequent inch of core depth will not cool as effectively as the previous inch due to the cumulative increase in temprtature of the "cooling airflow."

You may then run into issues with radiator cooling effectiveness since it's last in line

 

[hks-gst]

precision 750hp intercooler 31 1/2" L x 10 5/8" H x 3 1/2" D

 

[turbo addict]

3" thick intercoolers are almost too thick, i couldnt even imagine trying to flow air through a 4.5" thick intercooler.

NOTE: bigger is not always better.

I have a gt42-76 I need the flow through, and some of the supra guys are running a 5" thick core. Also you are not always in boost and while you are driving around getting cool air through the intercooler cooling the entire intercooler off and (in effect cool soaking) and with more mass the intercooler will take longer to heat soak, cooling until you heat the entire intercooler up.