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Old 02-22-2015, 12:47 PM   #1
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Default Intercooler mounting ideas

Am building mx5 powered kit car and coming up with an intercooling strategy is proving difficult. At the moment I have no intercooler and a saab wastegate actuator giving a nice low .3 to .4 bar (4-6psi). Have brought a bar and plate intercooler similar dimensions to the radiator but alas I can't think of a way to mount it. If you could look at my pictures and let me know if you have any great ideas. As you can see the nosecone tapers smaller towards the front. I have a bit of space above the radiator but not enough to allow the cooler to sit upright. I'm not completely opposed to cutting the cone and building it with fibreglass. My ideas so far:
A - I could mount the intercooler right way up, cut a lot across the top of the nosecone and build it up with a buldge to accomodate it.
B - Mount the cooler diagonally with one pipe top and one bottom. Then I only need to make a smaller hole in middle top and bottom and build around the protruding section (my favoured option at the minute).
C - Mount upside down and make a large cut in the bottom which would leave the top tidier.
D - Cut the factory made radiator brackets off and move the radiator back and down but I can't move very far and not sure if its enough.
E - Different intercooler. Location other then front mount.
F - ? Maybe one of you has an awesome idea!
I did experiment with a floor mounted intercooler but I suspect it did more harm then good as an interheater.



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Intercooler mounting ideas-20150222_144741_zpsd739f2d6.jpg   Intercooler mounting ideas-20150222_145035_zps30f87389.jpg   Intercooler mounting ideas-20150222_145020_zps5b742db9.jpg   Intercooler mounting ideas-20150222_145106_zpse12e7d27.jpg  
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Old 02-22-2015, 01:52 PM   #2
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Will the intercooler lay down, flat, above the radiator?
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Old 02-22-2015, 01:59 PM   #3
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Will the intercooler lay down, flat, above the radiator?
I think yes, above and mostly behind the radiator. You thinking a wrx style air scoop?
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Old 02-22-2015, 07:10 PM   #4
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That, or some kind of ducting from the bottom. Maybe a pair of NACA ducts on the nose panel?
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Old 02-22-2015, 07:20 PM   #5
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Originally Posted by nixapgt View Post
That, or some kind of ducting from the bottom. Maybe a pair of NACA ducts on the nose panel?
Only thing that would worry me about mounting there is that even with ducting it would be exposed to a lot of radiator heat as well
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Old 02-22-2015, 08:17 PM   #6
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What about an air to water setup. Not as efficient but looks like you have plenty of room for the heat exchanger.
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Old 02-22-2015, 08:59 PM   #7
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What about an air to water setup. Not as efficient but looks like you have plenty of room for the heat exchanger.
Good point! I thought of this before and must admit it slipped my mind so I'll look into it deeper. I wonder how much weight penalty you pay with the water in the system
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Old 02-22-2015, 09:26 PM   #8
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Good point! I thought of this before and must admit it slipped my mind so I'll look into it deeper. I wonder how much weight penalty you pay with the water in the system
I can't see where It'd be more than 5 lbs all in. Not sure if there's a limit to the boost level due to the thermal efficiency.
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Old 02-22-2015, 10:34 PM   #9
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At 4-6lbs of boost, I wouldn't worry about it too terribly much. At those levels, maybe even methanol injection would be a simpler plan.
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Old 02-23-2015, 12:39 AM   #10
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At 4-6psi you can actually forego the IC completely. My buddy does that with his Rotrex now (your first picture).

If you're planning on more boost, your second picture is probably the best solution IMO.
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Old 02-23-2015, 03:03 AM   #11
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At 4-6psi you can actually forego the IC completely. My buddy does that with his Rotrex now (your first picture).

If you're planning on more boost, your second picture is probably the best solution IMO.
No no I'm just running 4-6psi for now until I have intercooling to match. I want to run around 12psi when its sorted.
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Old 02-23-2015, 08:08 AM   #12
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what size is that core? 12x12x3?

I would do something like this in a MUCH smaller size:




and I'd think strongly about semi-v mounting it. Similar to what savington did in his racecar and this:





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Intercooler mounting ideas-tts3.jpg   Intercooler mounting ideas-andrew_kidd_miata_03.jpg   Intercooler mounting ideas-dscn1542.jpg  

Last edited by Braineack; 02-23-2015 at 08:18 AM.
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Old 02-23-2015, 02:16 PM   #13
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Some good ideas thank Brain (and others). It is around 12.5x12x3 core. I also have an 8x8x4 one from another project I think might fit. Not sure if thats big enough and I'm sure 4" thick can't be very efficient. I'm warming to the idea of a liquid/air set up but have heard they don't like sustained use. Also not sure if it would be ok to mount the radiator to the front of the engine radiator lest it soak up the heat (would be ok when underway but might have a negative effect when you get stuck in traffic).
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Old 02-23-2015, 02:29 PM   #14
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This is kind of a cool (no pun intended) concept;

Intercooler information - Build your own - Laminova

Might be worth an email to them.
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Old 02-23-2015, 02:31 PM   #15
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how much space is there between the fasica and the top of the radiator as as?
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Old 02-23-2015, 02:43 PM   #16
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how much space is there between the fasica and the top of the radiator as as?
Its around about 65mm or 2.5".
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Old 02-23-2015, 02:46 PM   #17
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Quote:
Originally Posted by bahurd View Post
This is kind of a cool (no pun intended) concept;

Intercooler information - Build your own - Laminova

Might be worth an email to them.
Very sexy! but I'm on a budget here - most my bits are secondhand
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Old 02-24-2015, 12:31 AM   #18
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Quote:
Originally Posted by luke2152 View Post
Some good ideas thank Brain (and others). It is around 12.5x12x3 core. I also have an 8x8x4 one from another project I think might fit. Not sure if thats big enough and I'm sure 4" thick can't be very efficient. I'm warming to the idea of a liquid/air set up but have heard they don't like sustained use. Also not sure if it would be ok to mount the radiator to the front of the engine radiator lest it soak up the heat (would be ok when underway but might have a negative effect when you get stuck in traffic).
How much boost you need while stopped in traffic?

The inner macgiver/ k.i.s.s. in me says just put rubber nipples over the top two radiator bolt holes and weld on (or have welded) 2 little 3 inch brackets onto the side of the intercooler so you can attach it to the bottom two bolt holes. Edit: I'm an idiot, forgot you don't have room, would you if you have 2 inch piping? Looking at it again my money's probably on mounting it upside down depending on how much you'd have to trim the body stuff. Or get a smaller intercooler or piping. That things a monster for your needs.

That last picture would drive me batshit crazy everytime I looked at my crooked fins, and would be harder to mount.
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Old 02-24-2015, 10:15 AM   #19
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I think I'd buy this:

cxracing.com: Turbo Intercooler 16.5"x11"x3", 3" Core: 11"x11"x3",2.5" Inlet & Outlet on One Side,3" Core


then do this:




two 45 bends would fit better under the fasica cover. I'd then build shrouding to direct airflow directly under and onto the IC.
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Old 02-24-2015, 10:29 AM   #20
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Would the IC seal against the face of the radiator?
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