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Old 10-22-2006, 11:42 AM   #1
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Default Intercooler Design Ideas....

Ok, carrying on from a previous thread, here is my ideas for routing from the turbo compressor to the intercooler over the top of the radiator.

My reasons for doing this are:

1. Shorter run with less bends
2. Did not want to do excessive mods to the bodywork that are associated with bending cutting and moving the radiator, brackets, A/C compressor etc.
3. Do not mind some slight cutting of my hood - again!

Pics coming now...
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Old 10-22-2006, 11:44 AM   #2
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This is the area under the hood that will need to be cut out.
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Intercooler Design Ideas....-hood_cut_area.jpg  
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Old 10-22-2006, 11:46 AM   #3
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Closeup of the area to be taken out.

Here I think it can be cut either side and then pressed back down, leaving a smooth transition from the front towards the rear.

The white circle is were the rubber bump stop touches the hood.
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Intercooler Design Ideas....-closeup_hood_cut.jpg  
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Old 10-22-2006, 11:50 AM   #4
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These are some problem areas that I see. Due to engine movement there may have to be some type of protection at the front to prevent the pipe or hose from being worn away.

The white arrow in the middle is where I will have to put in a small (10 - 15 degree) bend.

At the compressor outlet I have already shaped the base of the connection to provide a slight downward angle and the point where I will need to put in the bend will be where I go back to horizontal.
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Old 10-22-2006, 12:11 PM   #5
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Here is another look at the angles that I will have to make from the right side of the car.
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Old 10-22-2006, 12:13 PM   #6
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#1 - My biggest concern was would it actually all fit under the hood even after I remove the area. From this pic it looks ok, however I will get a lazer level and see if it actually is before I start.

#2 - Another look at where the pipe bends downwards. I will definatly have to put some protection at this point and maybe a hump hose somewhere between here and the compressor outlet to allow for more flexing. Not sure.

After that, its CUTTING TIME! Woo Hooo!

DB
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Intercooler Design Ideas....-fitment.jpg  
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Old 10-22-2006, 12:31 PM   #7
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Quote:
Originally Posted by da Bajan View Post
#1 - My biggest concern was would it actually all fit under the hood even after I remove the area. From this pic it looks ok, however I will get a lazer level and see if it actually is before I start.

#2 - Another look at where the pipe bends downwards. I will definatly have to put some protection at this point and maybe a hump hose somewhere between here and the compressor outlet to allow for more flexing. Not sure.

After that, its CUTTING TIME! Woo Hooo!

DB
Actually this setup was done on Barry Birdwell's Miata, Corky built him a very trick manifold that sat in the hood latch area. It was wider and flatter to help keep restriction to a minimum.

Mark
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Old 10-22-2006, 01:43 PM   #8
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looks like it fits nicely. A hump hose would be nice idea to replace the existing coupler with.

do you have the intercooler already? I know you were planning on a normal around the radiator exit. Just waiting for the rest of the build to be completed
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Old 10-22-2006, 02:40 PM   #9
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ill try and get some intercooler pics up.finished up my setup and diddnt put the front bumper back up yet.
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Old 10-22-2006, 03:56 PM   #10
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I don't see this working without modifying the radiator brackets to lower and tilt back the radiator. I have a 2000 so it may be different but I dont see how your hood could close.

The 90 degree bend over the rad looks like a sharp radius and way close to the hood. I think I used a 5" radius there. If you look at the TDR pic the bend starts farther back and has plenty of clearance up front.

For tubing out of the turbo, I used a 3" radius 180 degree that's cut at the 45 degree point. You then flip the 45 degree bend and weld it on so that you have a 135 degree bend and then a 45 going the other way. The net result is the tube going towards the front of the car is a perfect 90 degrees from turbo clocked straight up, but low enough for a straight shot over the rad.

Here's a pic of the TDR that it should look like.




I'll be working on my car next weekend and will take some pics of my intercooler plumbing.
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Old 10-22-2006, 04:54 PM   #11
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Yes, I have had a good look at the TDR setup and decided that with the kit I would be happy to do it, but trying to do it myself I do not want to have to make that many parts.

I am willing to cut the hood which will allow the bend to go down to the intercooler I hope with out moving the radiator. We shall see.

DB
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Old 10-22-2006, 11:16 PM   #12
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Here is an idea of how I think the pipe for the intercooler will run. The end pipes will be part of the Intercooler.

As I build the model I will post new pics.

DB
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Intercooler Design Ideas....-intercooler-pipe-setup.jpg  
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Old 10-23-2006, 09:24 AM   #13
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Here is an update with how I am going to have the intercooler done.

DB
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Intercooler Design Ideas....-intercooler-pipe-setup-2.jpg  
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Old 10-30-2006, 06:47 AM   #14
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Default More work done

So did some more work this weekend and have the following updates. First pic is the initial cut out that I did to allow the pipe from the compressor to go over the radiator and down to where the intercooler will be mounted. Pic 1 After test fitting I discovered that I would need to make it a little bigger and the second pic is the one that works. Pic 2

I put the pipes in to test this and guess what, it works perfectly! So no radiator move, not A/C radiator thing move! Easy as pie. Have to change the end tanks on the intercooler - the (looking towards the front of the car) left side will point up, and the right side will be plumbed in at the bottom. I will post a 3D generated pic of that later.

While I was doing this I had a piece of decorative aluminum hanging around and I thought - hey, that would fit over the top to help airflow through all the radiators! So I fabed one up and the final pic shows it fitted! Pic 3
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Old 10-30-2006, 06:54 AM   #15
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For some reason linked pics are not working for me, sorry for just posting links.
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Old 11-17-2006, 02:07 PM   #16
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Hi Da Bajan,

What diameter piping used on the compessor side to the intercooler?
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