Front Mount Intercooler

Blackcoog · 07-02-2007, 09:35 AM

I'm looking for a good front mount intercooler that will flow enough to support my supercharged 3L. Lets say my maximum hp need is 450whp (leaves good head room) and I'd like to have as little pressure drop as possible.

The one I have now that fits is 22" x 6" x 3" and I think that is with the end tanks. It can't be any longer but could be a few inches taller or even a little thicker. It if is taller the inlet and outlet need to be as close to the bottom as possible.

Currently the intercooler I have drops the boost from 11psi to 6psi at the intake. Obviously that is not acceptable.

Any thoughts or suggestions?

I currently have my blow off valve after the intercooler before the intake. If the intercooler is maxed out where does the extra air go that can't get through the intercooler? The compressor isn't making any surging noises from air being forced back to it which is where you'd think it would have to go. It almost sounds like I should put the BOV between the supercharger and the intercooler, but I may have a space issue trying to get it in there.

Blackcoog · 07-02-2007, 09:52 AM

Lots of good info on the site and they let you custom order what you want. Even ship the same day for more items.
Bell Intercoolers Air to Air Intercooler Assemblies

I called Bell intercoolers and went over my setup with one of their engineers. He said the smallest I can go is about 18"x12"x3.5" (core size). This has a 800 CFM rate which should be good for 450whp. The cost is..... $796.00

A mass produced one should be much cheaper like the one below for example (the larger of the two listed):

BoneHead Performance
(the 28" one should fit I'd have to double check)

FastCougar · 07-03-2007, 06:42 PM

Check out this eBay store: Just-Intercoolers

fordrule · 07-03-2007, 06:54 PM

good info

Unknown2k · 07-06-2007, 03:52 PM

hmm you have a problem there thats more then the intercooler. 5 psi is alot! Is your BOV leaking, or is there a crack in the intercooler. OR a hole from a rock? I've heard of .5 to 1 psi loss when people go bigger with the intercooler, but 5???

blustreak · 07-06-2007, 06:01 PM

Quote:

Originally Posted by Unknown2k

hmm you have a problem there thats more then the intercooler. 5 psi is alot! Is your BOV leaking, or is there a crack in the intercooler. OR a hole from a rock? I've heard of .5 to 1 psi loss when people go bigger with the intercooler, but 5???

I believe the problem is that the intercooler is too small and that's why the loss is so large.

Blackcoog · 07-07-2007, 12:34 PM

Car holds boost fine without the intercooler. It is definately the intercooler causing the drop. I'm looking into a larger one.

Unknown2k · 07-07-2007, 12:44 PM

Quote:

Originally Posted by blustreak

I believe the problem is that the intercooler is too small and that's why the loss is so large.

nope Boost is boost. If the intercooler is too small then the air is to hot thats it. The reason they list a a HP limit is the total amount of air that the intercooler can cool.

The reason I say this is B/c the intercooler i have gets heat soaked in this AZ sun but I'm not losin any psi.. just power from the hot air. but if i get a bigger intercooler the air will be cooler but I wil lose a little psi b/c the amount of air needed to fill the intercooler will be more..

pgtatx · 07-08-2007, 01:31 PM

Core efficiency is important... Both it's efficiency in ability to dissipate heat, and it's ability to flow air...

If you have 2 IC cores with the same dimensions... why does one produce a larger drop in pressure across the core than the other other one. If you look at a cross section of 2 cores... 1 being a name brand top core, and the other being an Ebay knock off, you'll see the answers.

Exterior dimensions alone will not tell you what the core will actually flow. Companies take guesstimated based on size, but reall companies actually test.

If an IC is too small or way too large (which is a common issue amongst the ricer community), you will end up with a not so fun situation.

If you have a turbo that pushes X amount of air, and then you have 5 ft of piping, and a huge core that flows XXX amount of air... you will end up woth significantly slower spool, and show a loss of pressure across the core. People think bigger is better, but that is not true...

If the turbo you have flows XXX amount of air, and you use an IC that flows X amount of air... you will be creating back pressure and significantly increasing the temp of the air. You may even see some some surging...

Find an optimally designed IC... good core and proper end tank design... and you will get the most out of the set up.

Unknown2k · 07-08-2007, 03:05 PM

Ya thats why I love seein the SRT-4 guys with there huge intercoolers and they just started to mod there cars.. turbo can't flow grea enough for that cooler.

07-02-2007, 09:35 AM	#1 (permalink)
Blackcoog 3L Install Maestro Join Date: Oct 2000 Location: Minneapolis, MN Posts: 4,606	Front Mount Intercooler I'm looking for a good front mount intercooler that will flow enough to support my supercharged 3L. Lets say my maximum hp need is 450whp (leaves good head room) and I'd like to have as little pressure drop as possible. The one I have now that fits is 22" x 6" x 3" and I think that is with the end tanks. It can't be any longer but could be a few inches taller or even a little thicker. It if is taller the inlet and outlet need to be as close to the bottom as possible. Currently the intercooler I have drops the boost from 11psi to 6psi at the intake. Obviously that is not acceptable. Any thoughts or suggestions? I currently have my blow off valve after the intercooler before the intake. If the intercooler is maxed out where does the extra air go that can't get through the intercooler? The compressor isn't making any surging noises from air being forced back to it which is where you'd think it would have to go. It almost sounds like I should put the BOV between the supercharger and the intercooler, but I may have a space issue trying to get it in there. __________________ Current Rides 1999 MTX Cougar, 3L Supercharged 325hp and 278tq 1999 SVT Contour, Ported 3L Visit: http://www.3lduratec.com For info on ready to drop in 3L's and our supercharger kit. Last edited by Blackcoog; 07-02-2007 at 10:59 AM.

07-02-2007, 09:52 AM	#2 (permalink)
Blackcoog 3L Install Maestro Join Date: Oct 2000 Location: Minneapolis, MN Posts: 4,606	Re: Front Mount Intercooler Lots of good info on the site and they let you custom order what you want. Even ship the same day for more items. Bell Intercoolers Air to Air Intercooler Assemblies I called Bell intercoolers and went over my setup with one of their engineers. He said the smallest I can go is about 18"x12"x3.5" (core size). This has a 800 CFM rate which should be good for 450whp. The cost is..... $796.00 A mass produced one should be much cheaper like the one below for example (the larger of the two listed): BoneHead Performance (the 28" one should fit I'd have to double check) __________________ Current Rides 1999 MTX Cougar, 3L Supercharged 325hp and 278tq 1999 SVT Contour, Ported 3L Visit: http://www.3lduratec.com For info on ready to drop in 3L's and our supercharger kit. Last edited by Blackcoog; 07-02-2007 at 12:03 PM.

07-03-2007, 06:42 PM	#3 (permalink)
FastCougar In search of more boost! Join Date: Nov 1999 Location: Kearneysville, WV Posts: 8,507 Images: 743	Re: Front Mount Intercooler Check out this eBay store: Just-Intercoolers __________________ 1999 Mercury Cougar - Turbo'd 3L. Status: Parting out car: Engine for Sale \| Trans for Sale Power: 391.9 hp @ 6750 rpm \| 374.2 lbs/ft. @ 4250 rpm \| boost @ 11 psi For Sale: 19" Konig Verdicts with Toyo ProxesFZ4 225/35ZR19 Tires - $700 shipped!

07-03-2007, 06:54 PM	#4 (permalink)
fordrule back in the states Join Date: Dec 2002 Location: Clarksville, TN/ Fort Campbell, KY Posts: 5,627 Blog Entries: 1	Re: Front Mount Intercooler good info __________________ We Can Rebuild Her 3L MoToR:02 3L, SVT UIM/LIM/TB/INJ/CAMS, st200 springs, pnp, xcal 2,PRP, hi-flo cat HMS prepped mtx-75:quaife, slick shift forks, "koated kogbox", focus tower, B&M. car mod: GMK HP CF CAI, weapon r headers, relocated battery, st200 RTSB, OMP FTSB, GC, roush swaybar, Audi RS6 HIDs, angel eyes, CF fenders/hood/mirror caps/ eclipse gas door, painted taillight covers/headlight inserts, WW grill,18" centerline,Full Roush lip Kit and spoiler, 17" Roush Ver. 2 wheels.

07-06-2007, 03:52 PM	#5 (permalink)
Unknown2k TT ROADSTER Join Date: Oct 2005 Location: Iraq..... GREAT :( Posts: 1,244 Images: 1	Re: Front Mount Intercooler hmm you have a problem there thats more then the intercooler. 5 psi is alot! Is your BOV leaking, or is there a crack in the intercooler. OR a hole from a rock? I've heard of .5 to 1 psi loss when people go bigger with the intercooler, but 5??? __________________ THE OLD CAR http://www.cougardb.com/car.php?id=unknown2kcat

07-07-2007, 12:34 PM	#7 (permalink)
Blackcoog 3L Install Maestro Join Date: Oct 2000 Location: Minneapolis, MN Posts: 4,606	Re: Front Mount Intercooler Car holds boost fine without the intercooler. It is definately the intercooler causing the drop. I'm looking into a larger one. __________________ Current Rides 1999 MTX Cougar, 3L Supercharged 325hp and 278tq 1999 SVT Contour, Ported 3L Visit: http://www.3lduratec.com For info on ready to drop in 3L's and our supercharger kit.

07-08-2007, 01:31 PM	#9 (permalink)
pgtatx Moderator Join Date: May 2001 Posts: 4,281	Re: Front Mount Intercooler Core efficiency is important... Both it's efficiency in ability to dissipate heat, and it's ability to flow air... If you have 2 IC cores with the same dimensions... why does one produce a larger drop in pressure across the core than the other other one. If you look at a cross section of 2 cores... 1 being a name brand top core, and the other being an Ebay knock off, you'll see the answers. Exterior dimensions alone will not tell you what the core will actually flow. Companies take guesstimated based on size, but reall companies actually test. If an IC is too small or way too large (which is a common issue amongst the ricer community), you will end up with a not so fun situation. If you have a turbo that pushes X amount of air, and then you have 5 ft of piping, and a huge core that flows XXX amount of air... you will end up woth significantly slower spool, and show a loss of pressure across the core. People think bigger is better, but that is not true... If the turbo you have flows XXX amount of air, and you use an IC that flows X amount of air... you will be creating back pressure and significantly increasing the temp of the air. You may even see some some surging... Find an optimally designed IC... good core and proper end tank design... and you will get the most out of the set up. __________________ -Sold: '99 Cougar V6 MTX with the craziest tranny ever. -Sold: '04 Black Subaru Impreza WRX STi MD 3" Stealthback/ Prodrive Axleback , Perrin TMIC/MAF Pipe/Panel Filter/Catch Can, Borla SS Header, Worx adjust. BOV, Tein SSP Coilovers, Cobb AP, RB Slotted rotors, Hawk Pads, Cusco Type 2 lower bar, Beatrush Front lower bar/prop shaft bushings/rear diff support bar, Whiteline Anti-Lift kit/steering rack bushings, AEM/Autometer Gauges... -2005.5 Audi S4 6MT... Brilliant Red

07-08-2007, 03:05 PM	#10 (permalink)
Unknown2k TT ROADSTER Join Date: Oct 2005 Location: Iraq..... GREAT :( Posts: 1,244 Images: 1	Re: Front Mount Intercooler Ya thats why I love seein the SRT-4 guys with there huge intercoolers and they just started to mod there cars.. turbo can't flow grea enough for that cooler. __________________ THE OLD CAR http://www.cougardb.com/car.php?id=unknown2kcat

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