Contour Enthusiasts Group Archives Forums Modifications Forced Induction Building a Custom Water - Air Intercooler

Originally posted by Swazo:

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I'm starting to think maybe it's best that I do have a T3/T04E .57/.63, I don't think I'll be seeing much past 7K anyway.

I do think I'll be able to have the inlet snout sitting right above the turbo, so no bend to enter the IC. The outlet snout can also be placed for a direct oulet for the TB. I just have to keep the turbulance down and make use of all the surface area of the IC core as possible.

Originally posted by livinsvt:

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Sounds good man. I myself would much rather a tank mounted in front of th car. Maybe a stealth install in the front bumper

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I will have to see if I can mount the tank under the actual bumper, behind the bumper cover. I'd also have to make a filler neck w/ a marine style screw-in fuel cap in the engine bay

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You guys have pictures of my aluminum intercooler resevoir and you can see that it will fit easily in the space by the engine coolant resevoir. It doesn't have to be a fancy aluminum container, it can be a plastic cylinder or wide diameter PVC sewer pipe with end caps cemented on and fittings mounted. Remeber, it will never get over 220F so PVC for liquid puposes will be fine.

I've already got enough measurments to PROVE that the small tank for the intercooler is superior to the large volume trunk mount in all ways except for using ICE. Using ICE is a pain in the ass by the way.


Maximum loads on the stock rods:

These stock rods will handle 400HP unless there is a defective one and will probably hold more than that.
Assume the 7000 rpm safe limit for the rods and pistons.

Take the torque that I already hit with the stock rods, 330 FT-lbs at the wheels.

Calculate the horsepower from that torque but using a higher rpm:

HP=TQ*RPM/5252

HP= 330*6750/5252

HP= 424 HP

The secret is keeping the torque up as the engine revs up.

Now the pistons are another story. I know that the later pistons are doing just fine so far but I have no idea what the end result will be. I'm guessing with a good tune they can still sustain 400 HP like the rods but if there is any pinging or even borderline detonation at those loads it will probably crack one. Forged pistons are a safe bet but rods I am no longer worried about. I have been running on the 01 3L escape block and it has been excellent so far. No oil burning, no excessive blow-by, quiet and smooth. The fuel economy is 26 MPG on the highway and about 15 in the ciy. This is with 7 pounds of boost normal and 9 pounds for extra 'fun'.
The car is running awesome, sounds great and only needs another set of tires.

So don't worry yourself about an easy 350HP or so.

I'll put it this way, my car runs so well, is so complete that I am getting bored with it. I am in need of a new challenge. I am even contemplating selling the car just so I can take the money and buy a new BMW to start on.
never satisfied I guess.

Tom

By the way, I am home on leave for two weeks before I return to Iraq. I'll be checking CEG a bit more often to help with advice during the time.