To duct or not to duct...FMIC pix

[snowborder714]

Here is my ducting .No more overheating on the highway after this.

Any more pictures of this?

 

[TSi Kid]

+1 on the pictures.

 

[phunny]

Here's an update so far;

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The blue tape is just for holding things in place. I chose this thick plastic so I can actually use one solid piece with many complicated cuts. The install should be done on friday

 

[LiquidX]

Good work so far Charlie. Keep it pictured up

 

[BIGBLAZE79]

So are you using the crash beam?

 

[phunny]

Good work so far Charlie. Keep it pictured up

Will do man , it's really coming along. The greatest part is the template I made for the passenger side took very little modifying the driver side

So are you using the crash beam?

Yeah, I just had it off for ease of fabrication, same with the headlights.

 

[BIGBLAZE79]

Did you cut the top and bottom of the beam out to increase airflow around the inner cooler? I had to cut the bottom but now I am at the point I either cut holes in the bumper or I was thinking about cutting the top part of the beam out. currently the inner cooler touches the top part of the crash beam so no air car go around it. I removed the bumper and it fixed my overheating on the highway. Road conditions 105F 65Mph A/C on. With bumper on I get about 10 miles before the temp starts to go above normal.

 

[phunny]

Did you cut the top and bottom of the beam out to increase airflow around the inner cooler? I had to cut the bottom but now I am at the point I either cut holes in the bumper or I was thinking about cutting the top part of the beam out. currently the inner cooler touches the top part of the crash beam so no air car go around it. I removed the bumper and it fixed my overheating on the highway. Road conditions 105F 65Mph A/C on. With bumper on I get about 10 miles before the temp starts to go above normal.

Yeah that's why it was cut out. Do you have yours ducted or not?

 

[BIGBLAZE79]

Oh yea, Ducted on both sides and the bottom also used foam strips to seal everything, New OEM water pump, new OEM thermostat, New Head and gasket, 80/20 water/AF with red line water wetter, Heat wrapped 2G manifold/turbo/O2/downpipe/water pipe, stock heat shields and custome O2 heat shield, 3 Fans: one stock puller, one spal 9" puller and one cheap pusher on AC condensor (ON all the time with DSMlink), Aluminum radiator and cut holes in the hood. I just wanna be able to run the AC when its 115F outside

 

[phunny]

Oh yea, Ducted on both sides and the bottom also used foam strips to seal everything, New OEM water pump, new OEM thermostat, New Head and gasket, 80/20 water/AF with red line water wetter, Heat wrapped 2G manifold/turbo/O2/downpipe/water pipe, stock heat shields and custome O2 heat shield, 3 Fans: one stock puller, one spal 9" puller and one cheap pusher on AC condensor (ON all the time with DSMlink), Aluminum radiator and cut holes in the hood. I just wanna be able to run the AC when its 115F outside

That's insane man. The only thing I could think of is that those 9" fans just can't pull enough air. What bran are they and what cfm are they rated for?

 

[LiquidX]

I'd agree, the 9" SPAL isn't enough forma radiator. It would be excellent mounted to a SMIC and put on a switch to keep the IC cool during traffic. Other than that, I think it is hurting your system by adding an area of increased air resistance.

Not only that but if one fan is blowing more air, the smaller one isn't going to pull through any more air.

 

[BIGBLAZE79]

I have the stock AC fan that is on the passenger side, It moves a ton of air. The 9" is all I could fit between it and the external waste gate. The 9" is a be cool fan rated at 740 CFM (for some reason I was thinking spal). The pusher came with the punishment racing radiator so I don't know what the cfm of that one is. The pullers are moving way more air than the pusher in the front. I just thought it would help some pushing the air.

There is one thing that is bothering me, When I turn the fans on. There is an area of the radiator that is not covered by a fan or shroud because of the external waste gate. If I take a small peice of paper and stick it there. It will suck up to it and stay. I think this is not helping because engine air is on that side. I was thinking about taking sheet metal and covering it up to see if that helps.

 

[phunny]

I have the stock AC fan that is on the passenger side, It moves a ton of air. The 9" is all I could fit between it and the external waste gate. The 9" is a be cool fan rated at 740 CFM (for some reason I was thinking spal). The pusher came with the punishment racing radiator so I don't know what the cfm of that one is. The pullers are moving way more air than the pusher in the front. I just thought it would help some pushing the air.

There is one thing that is bothering me, When I turn the fans on. There is an area of the radiator that is not covered by a fan or shroud because of the external waste gate. If I take a small peice of paper and stick it there. It will suck up to it and stay. I think this is not helping because engine air is on that side. I was thinking about taking sheet metal and covering it up to see if that helps.

I'd love to see if a setup like this would help your situation, I would personally think so but only a test run would tell. You could easily get a piece of aluminum and have a couple holes cut out.
‪Radiator Fan & Shroud CFM Demonstration‬‏ - YouTube

 

[BIGBLAZE79]

This is a pic of when I first installed the turbo, stainless O2 housing, external waste gate and radiator all at the same time. The fans that came with the radiator melted by the exhaust heat. That's when I had to install the stock one and buy a 9" and used the unmelted one as a pusher on the otherside of the A/C condenser.

 

[phunny]

I think I know why you melted the fans and why you are overheating. Since air takes the path of least resistance, when you're fans are on(especially the drivers side one) and you don't have a shroud that covers the whole radiator you are sucking air from the manifold through the radiator and then using that air to cool the radiator. Now this is a theory but I'm really thinking it could be your problem. So something like the setup in this video would likely fix it.

 

[BIGBLAZE79]

The problem is there is seriously like 1 inch between the external waste gate and radiator. If I built a fan shroud I would only be able to fit one big fan or maybe two small 12", prob smaller than that. IDK I spent $200 on the 9" what a kick in the ba!!s.

 

[phunny]

The problem is there is seriously like 1 inch between the external waste gate and radiator. If I built a fan shroud I would only be able to fit one big fan or maybe two small 12", prob smaller than that. IDK I spent $200 on the 9" what a kick in the ba!!s.

Wow that's close, but the addition of the aluminum depending on how you mount it would either take up 0" or at max 1/4".

 

[phunny]

Still waiting on fans and I have the FMIC at Frontline Fabrication for a little modification to really clean things up a bit. I really didn't want to use take to hold everything in so I got some aluminum "U" channel and he's welding it all around the FMIC so it will hold my ductwork in place. It will be welded right on the FMIC were the black ductwork ends.

 

[bertrenolds]

Somehow that looks like it's gonna cause more heat issues then it will prevent.

 

[phunny]

Somehow that looks like it's gonna cause more heat issues then it will prevent.

That's a pretty bold comment that contradicts everything on the site, please explain your thoughts behind it. This is my first time ducting a setup so all theories are welcomed and appreciated .

 

[TSITurbo95]

Somehow that looks like it's gonna cause more heat issues then it will prevent.

Negative ghost rider! Think about it, when hes driving, air will enter the fmic, and then force itself through the radiator. Where as he did not have the shroud before, air would enter the intercooler and exit the sides/top as it is the path of least resistance.

 

[airmail96]

Agreed I think it is going to be pretty awesome.

 

[gst fat]

Agreed I think it is going to be pretty awesome.

Looks really good, while you driving it will help! But what happens at idle or heavy track, that might get pretty hot, only thing that might help at idle for that is running 4 fans, 2 pullers and 2 pushers but who knows I might be wrong, I'll post pics of my setup soon

 

[phunny]

Looks really good, while you driving it will help! But what happens at idle or heavy track, that might get pretty hot, only thing that might help at idle for that is running 4 fans, 2 pullers and 2 pushers but who knows I might be wrong, I'll post pics of my setup soon

Not sure to be honest. The 2 fans I purchased will pull 3000cfm and that's rated after the radiator . As soon as I get the fans in I'll have some logs and information.

 

[ceedawg]

Still waiting on fans and I have the FMIC at Frontline Fabrication for a little modification to really clean things up a bit. I really didn't want to use take to hold everything in so I got some aluminum "U" channel and he's welding it all around the FMIC so it will hold my ductwork in place. It will be welded right on the FMIC were the black ductwork ends.

Wow nice! I think I will have to do this. I do have I believe three fans though. One for push and two on the motor side of the car for pull.