Factory Intercooler Dimensions

[aps]

Peter,

The design consideration as yours was I would assume, was to have a kit that provided a minimum amount of pressure drop, while also removing as much heat as possible from the charge air stream, and also while not requiring cutting of body panels nor removal of standard Ford safety features..

Hyperflow are designing this intercooler for the mass market, so will follow a very similar design philosophy.  That being said, I do realise the issues regarding 'excessive turbo pressure' which result from the wastegate being too small to flow the required amount of exhaust gas in a modified application.

The wastegate will be modified in order to avoid this excessive pressure buildup.

Good on you for pointing this important fact out though, as most people wouldnt neccessairly know this.

Thanks,

Kris.

Well that's partly correct.

The design criteria is to minimize the pressure drop (not just the intercooler, but the entire system including the plumbing) whilst reducing the charge air temperature to as close as possible to ambient air temperature.

The other consideration is to match the Intercooler's air charge passages to that of the turbo charger's mass air flow, which is rated in lbs of air per minute. To do this you need to know the maximum air flow of the turbo charger at the highest pressure ratio (high boost level). This is no 5 minute exercise and you need the turbo charger's compressor map to calculate the correct intercooler design parameters.

In addition, the intercooler's external air fins and the intercooler cores thickness must be designed to allow sufficient air flow to the radiator - otherwise the engine may over heat in high load/rpm conditions.

If you go too thick in the intercooler core and or get the external air finning design wrong, you have a disaster on your hands through high engine temperature.

Peter

APS

[Falchoon]

No offense CnC, but it sounds like you're trying to re-invent the wheel. Just buy an intercooler from APS or someone simiar that has already gone to the trouble and expense of working out what's going to be the best thing for the job. Just get on and enjoy driving the car and let whatstherename buy their own vehicle for R&D.

[CnC]

Firstly im not designing it, Hyperflow is, and secondly its not costing me anything, so why would I go and buy it?

And finally even if I wanted to buy it, I would need to buy it in the Phase III kit which isnt available.

So no offence taken, and good luck in your own endevours..

[hypnodoc]

Doc, glad to hear your happy with the GT, now start by pulling off the injection and bolting on the single plane high rise manifold with the 750 double pumper HOLLEY, and get into the true GT spirit!

Regards

Peter

Aaaaahhhhhhhhhhhhhhhhhh.

No Peter, no, no, no ,no. Not to a GT, mate this car doesn't need anything, (well except the cold air induction, BMC, and underdrive pulleys it already has).

Have thrown another bundle of money at Ford for a series 2 T. They reckon Oct Nov.

That one will come to Melb, and YES you can play with it

[aps]

Aaaaahhhhhhhhhhhhhhhhhh.

No Peter, no, no, no ,no. Not to a GT, mate this car doesn't need anything, (well except the cold air induction, BMC, and underdrive pulleys it already has).

Have thrown another bundle of money at Ford for a series 2 T. They reckon Oct Nov.

That one will come to Melb, and YES you can play with it

Hey Doc, the ford dealer must love you, a new GT and a new T on order, keep up the good work lord knows we need the employment in Victoria.

Peter

APS

[aps]

Firstly im not designing it, Hyperflow is, and secondly its not costing me anything, so why would I go and buy it?

And finally even if I wanted to buy it, I would need to buy it in the Phase III kit which isnt available.

So no offence taken, and good luck in your own endevours..

You mean to say that hyperflow doesnt have their own engineering T?????

Well I am very surprised, talk about engineering on the run/cheap. Just borrow a car for a few days, and hey PRESTO, jobs done!

[hypnodoc]

new T on order, keep up the good lord knows we need the employment in Victoria.

Peter

APS

Not to mention the $28000 it cost me for my girls Zetec. Ahhhhhhh, now I realise what I've done. I might have to write myself a commitment order and get the boys in white coats around.

July 03 - Jan 04 has been an exxxy time. But as I read somewhere once, "Use your mouth to make your money, and your hands to have your fun". There isn't anything quite so much fun as hanging onto the leather bound steering wheel in one of these babies, whether it be a T or a GT.

[OzWRX]

Hey Pete,

says here that with intercooling bigger is better

http://www.airpowersystems.com.au/wrx/my01.../dr650_fmic.htm

but here you write:

"Be careful as bigger is not always better, we went as big as we dared (will support 650 horse power) any bigger and say goodbye to any control of the turbo pressure. Just trying to save you a lot of grief and wasted time."

OzWRX

[aps]

Hey Pete,

says here that with intercooling bigger is better

http://www.airpowersystems.com.au/wrx/my01.../dr650_fmic.htm

but here you write:

"Be careful as bigger is not always better, we went as big as we dared (will support 650 horse power) any bigger and say goodbye to any control of the turbo pressure. Just trying to save you a lot of grief and wasted time."

OzWRX

OzWRX, you missed the most vital part of my post: :woahidea:

Now this fact is only relevant to the xr6t and should not be automatically applied to any other intercooler application. Ford utilise the merely adequate stock intercooler as part of their turbo pressure control system.

Would pay you to read the entire thread to in order to contribute effectively to the forum. As I have said before, the XR6T is unique in its intercooler requirements and should not be compared to the WRX/STI/GTR/Porsche/etc...etc.... intercooler specifications.

Ultimately you need to have control of turbocharger pressure, otherwise you may end up with a major electrical problem. That is the conrod knocking the alternator off the cylinder block - as this is not the desired affect of efficient intercooling.

I hope that this clarifies the discussion as we are, after all talking about the Falcon XR6T.

Peter

APS

PS OzWRX, you wouldn't happen to be Kevin who operates hyperflow by any strange coincidence? The same Kevin who first posted on this forum 10 days ago and opened with this smelly statement about the mighty XR6T:

The Falcon is a big family car and nothing else....you flog it and it will break

Trade the thing on a new STi...and feel what driving is all about...I guarentee you wont go back...

Kevin

[CnC]

Firstly im not designing it, Hyperflow is, and secondly its not costing me anything, so why would I go and buy it?

And finally even if I wanted to buy it, I would need to buy it in the Phase III kit which isnt available.

So no offence taken, and good luck in your own endevours..

You mean to say that hyperflow doesnt have their own engineering T?????

Well I am very surprised, talk about engineering on the run/cheap. Just borrow a car for a few days, and hey PRESTO, jobs done!

Er not quite Peter I think you miss the point. Obviously Hyperflow do have their own engineering facility, after all they design and build quality intercoolers for a number of other cars already.

They will be using my car for a week to develop their kit, I am not sure what is so hard to understand about this? (It really is quite a simple concept).