New turbo garrett GT 25/30r turbo setup

[twin eng, twin turbs]

With the turbo in place and onto plumbing the intercooler i cant help but think that replacing the air to air intercooler and plumbing with a water to air intercooler mounted directly above the turbo and striaght into the throttle body is going to be far more efficient.

Not only top end power but also drivabilty and turbo lag would all improve with such a setup....

Even coolant temps would drop without the air flow restriction in front of the radiator. So im going to design and manufacture a water to air intercooler setup.

Pics to follow shortly..

[Jarred]

there's a bloke on vortex doing a 20VT in a mk 1, with an AWIC, if you need some inspiration

[Mika]

I'm using a WAIC for my pulsar for the same reasons...as well as the fact that I have a rare factory front bumper on it that I don't want to hack to fit a FMIC.

Only disadvantages I can think of will be that it won't cool as well as a front mount air to air on circuit on hot days, and the extra current draw from the water pump. I'm actually thinking I should get a temp sensor to keep an eye on charge temps just so I know if the pump or a hose fails before it's too late.

[POLARBEAR666]

With the turbo in place and onto plumbing the intercooler i cant help but think that replacing the air to air intercooler and plumbing with a water to air intercooler mounted directly above the turbo and striaght into the throttle body is going to be far more efficient.

Not only top end power but also drivabilty and turbo lag would all improve with such a setup....

Even coolant temps would drop without the air flow restriction in front of the radiator. So im going to design and manufacture a water to air intercooler setup.

Pics to follow shortly..

How about this for inspiration.

[Spyda]

Cant wait man. Love the work your puting in to it, we need more mk2s like this.

[twin eng, twin turbs]

Thanks guys, im feeling inspired!

Im half way through manufacturing the water to air intercooler
now.. The core size is 250mm wide 300mm deep and 80mm thick garrett tube and fin design. It's very tricky tig welding the end of the core that has been shortened down to suit, the tubes are 0.5mm wall thickness and i have had to seal between them. Ill be pressure testing the core before completing the end tanks to ensure no leakage is present once i machine fittings to suit and tig them on. In the photo it is in the very rough stages of manufacture and will sit further back towards the fire wall once the coil is relocated.

[gldgti]

With the turbo in place and onto plumbing the intercooler i cant help but think that replacing the air to air intercooler and plumbing with a water to air intercooler mounted directly above the turbo and striaght into the throttle body is going to be far more efficient.

Not only top end power but also drivabilty and turbo lag would all improve with such a setup....

Even coolant temps would drop without the air flow restriction in front of the radiator. So im going to design and manufacture a water to air intercooler setup.

Pics to follow shortly..

hey mate -
how will you cool the water? i mean, you'll need some kind of heat exchanger for that.... so where will it go?

i've always understood water-air IC setup from a space restriction perspective, or wanting to decrease lag, or for one-off type scenarios like drag racing. but, from a thermodynamics point of view, it doesnt make any sense to me to use a water to air setup.

just interested to hear your htoughts on it - for me - i see the cons - more complex, more components, heavier, etc etc. i can see why you might improve (in some respects) top end power, and drivability (having a shorter, more flow efficient inlet tract) but on the flip side, you wont achieve the same kind of inlet temperature reductions right across the board as is achieved with air-air.... i guess there are trade off's with all setups, and i can certainly see the "cool" factor with your idea.

good luck

cheers

[Preen59]

Looks good so far dude.


I'd just use methanol and a blower.. But hey, that's just me..

[twin eng, twin turbs]

Ill be mounting a heat exchanger with its own thermo fan in front and to the side of the radiator to cool the water in the intercooler using a high volume low pressure electric water pump approx 5psi to circulate the water

On the technical side a water to air intercooler is actually proven to be more efficient in every way than an air to air cooler as long as it is setup correctly. I have read a back to back test on the same car with an air to air core and water to air core using PWR products. The test messured inlet temps before and after the core and flow restriction through them in real driving conditions. The air to air messured a very marginal pressure drop across the core compared to the water to air core. The water to air gave better air temperature reduction across the entire rev and speed range. With low speed driving an air to air core returned much higher inlet temps. The real shock you will find is they calculated that an air to air core would have to be 4.2 times the surface area to acheive the same temperature dropb as a water to air core...

[gldgti]

Ill be mounting a heat exchanger with its own thermo fan in front and to the side of the radiator to cool the water in the intercooler using a high volume low pressure electric water pump approx 5psi to circulate the water

On the technical side a water to air intercooler is actually proven to be more efficient in every way than an air to air cooler as long as it is setup correctly. I have read a back to back test on the same car with an air to air core and water to air core using PWR products. The test messured inlet temps before and after the core and flow restriction through them in real driving conditions. The air to air messured a very marginal pressure drop across the core compared to the water to air core. The water to air gave better air temperature reduction across the entire rev and speed range. With low speed driving an air to air core returned much higher inlet temps. The real shock you will find is they calculated that an air to air core would have to be 4.2 times the surface area to acheive the same temperature dropb as a water to air core...

4.2 times the size they used, or 4.2 times the size of the water/air one they used?

btw - thanks!

[twin eng, twin turbs]

4.2 times the size of the water to air they used.. In comparison to the PWR water to air coolers available my core will flow in excess of 650hp not that my engine will make anywhere near that power. I WISH

[gldgti]

4.2 times the size of the water to air they used.. In comparison to the PWR water to air coolers available my core will flow in excess of 650hp not that my engine will make anywhere near that power. I WISH

ahh thanks mate! yeah, makes sense.... and correllates well with my experiments and experience of intercoolers - for me, bigger always seems to be better.... though, i can live with 'lag', since i can run such a small turbo just goes to show, so many different factors can be considered to get just the right option

[twin eng, twin turbs]

Manufactured the turbo outlet pipe to the water to air intercooler, it expands from 50mm to 65mm around 180 degrees offset at 45 degrees. Trickey to make and will be polished when tig welded to the intercooler.

[twin eng, twin turbs]

Machined up the mount for my sequential HKS blow off valve today, o'ring in the base to seal against and circlip groove to retain in place. This will be tig welded under the endtank of the intercooler out of sight of the defecting eyes of the boys in blue!

[twin eng, twin turbs]

I replaced the factory water to oil cooler with a 19 row air to oil cooler mounted under the radiator support panel, the sandwitch plate houses a thermostat and AN 10 braided lines connect them. The aluminium panel beneath will ensure air goes through the radiator instead of under it.