Intercooler Dimensions

Just a thought, would like some expert advice on this.

the standard AGU/1.8T/20vt intercooler is a side mount with dimensions
183mm x 190mm x 85mm = 2955.45cm2

so i am assuming to fit a 20vt into a mk1 the existing intercooler cannot be used to do location and size etc.

everyones saying use a sprinter one, but the size and dimensions for that is
815mm x 190mm x 85mm = 13162.25cm2

hugely different, with more piping in the mk1, isnt this a massive loss in power? and should an intercooler which has similiar total volume be used?

I think the original intercooler fitted to those engines was a bit naff mate.

The sprinter ones are massive and overkill IMO. Have a read of my build thread there's a bit in there about intercoolers. I have one for sale too.

Smudger

get yourself either of these

http://www.toyosports.co.uk/fmic-ffront-mount-turbo-intercooler-type-f-410x155x65mm-5799-1042-p.asp

http://www.toyosports.co.uk/fmic-ffront-mount-turbo-intercooler-type-s-550x140x65mm-5999-605-p.asp

they fit nice in front of rad.

also piping kit

http://www.toyosports.co.uk/25-turbo-intercooler-pipe-piping-diy-kit-64mm-blue-6499-1045-p.asp

what turbo you running? ko3 or ko3s 2 inch or 2.25 piping be best. the ones above are 2.5ich as im running a k04 hybrid they do sell 2 inch and 2.25 also they in brum can collect

Probably go with the Focus ST intercooler, which fits nicely behind the grille.





657mm x 157mm x 40mm = 4125.96cm2

Here's the place I got my intercooler from…..

http://www.ebay.co.uk/itm/230879020680?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649

It's not solely about area of the intercooler, end tank design, fins per area, placement in air stream all make big differences in terms of efficiency. I'd stick with something with alloy end tanks, especially if playing with the boost, no plastic rubbish that can crack. Front mounted ftw.

This seems okay, decent end tank design:

http://www.ebay.co.uk/itm/HONDA-CIVIC-ALUMINIUM-BAR-AND-PLATE-INTERCOOLER-/350444717297?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item51982204f1

Not too keen on the intercooler you posted, too much restriction on air flow as it has to turn on entering the cooler

I see, tou still have to put 90 degree enda for the mk1 fitment.

In terms of gas flow dynamics a near 90 degree bend integrated into the end tank would cause substantial reduction in velocity and create more turbulence too. Many talk about the added "lag" associated with adding more tubing but when the incoming air is travelling at tens or even hundreds of feet per second it is generally negligible if you're only talking a few extra inches.
With the tubing being bent outside the end tank you can substantially reduce the angle although there are always packaging constraints.

I'll dig out the flow dynamics tests i've done but I can always change the values to deal with various orifice dimensions and flow rates.

This is something like using wider intercooler tubing to a narrower one then to a larger again like a throttle body, or simply a bump in your intercooler piping.

Various values are inputted to see what flow is like and it gives you a timed performance


When the values are changed like velocity or even the chemical composition it produces reactions and changes, this VR6T one was for FI I did a while ago and heat build up from restriction can be seen a touch compared with above (more red)


Values are changed further (I think in this test it was to simulate an increase in boost/velocity) and you can then see at what point changes occur like restrictions/turbulence etc


As said this was just some 2D flow dynamics testing I did ages ago but it gives you an idea of why tuners go for less bends or less sharp angles.