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  #1  
Old 01-04-2006, 04:26 AM
Brandon314159
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w126 Body 300SD Water/Air Intercooler Project

Hey all,

Well my long set off task of building the tanks for my water/air intercooler has finally come to near completion. With a modified intake manifold, modified turbo compressor, and some odd all aluminium Audi intercooler, I have just about got the project parts all assembled.

I'll basically be outlining here what I have done to build this unit, some basic dimensions, and the EGT cooling gains offered by this setup. With an already modified/adjusted injection pump I cannot dyno the actaul changes in output power however I do have solid EGT numbers with which I can compare once the unit is installed.

The following posts will have progress/parts/updates.

Thanks!

(BTW Questions or Comments much appreciated)
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  #2  
Old 01-04-2006, 04:32 AM
Brandon314159
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The modification of the intake

Here you can see that we started out with a perfectly stock intake manifold for a 300SD. The one I had was VERY dirty and full of EGR crud so we cleaned it out. Using oxy-acetylene caused the carbon/oil goo to burn out and actually left the intake nearly spotless. A quick pass through the sandblaster cleaned it all up nice and prepped it for TIG welding of a new intake port.

NOTE: You must be careful when using this method to not get the intake TOO hot or else you could actually melt it.
Attached Thumbnails
w126 Body 300SD Water/Air Intercooler Project-picture-001.jpg   w126 Body 300SD Water/Air Intercooler Project-picture-002.jpg   w126 Body 300SD Water/Air Intercooler Project-picture-004.jpg   w126 Body 300SD Water/Air Intercooler Project-picture-005.jpg  
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  #3  
Old 01-04-2006, 04:41 AM
Brandon314159
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Cutting of the Intake Manifold

Here you can see the modifications made to the intake so that the intake port angle can be changed. I found early on that the stock intake had a very poor angle if I was ever going to hook up anything besides the turbo directly to the intake. Thus we made this.

Using a chop saw we carefully cut off parts of the intake to make a surface with which to mate the snout. The part we used as a hose hookup was actually a fuel/chemcial adaptor for aviation/farms use but it works fine for our project. At approximately 2.5" diameter it was perfect. We cut that up and got the intake ready for TIG welding.

Notes: German aluminium is a lot nicer than the crap that pipe was made out of.

BTW that's dad in the photos running the chopsaw.
Attached Thumbnails
w126 Body 300SD Water/Air Intercooler Project-picture-006.jpg   w126 Body 300SD Water/Air Intercooler Project-picture-007.jpg   w126 Body 300SD Water/Air Intercooler Project-picture-009.jpg   w126 Body 300SD Water/Air Intercooler Project-picture-013.jpg   w126 Body 300SD Water/Air Intercooler Project-picture-014.jpg  

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  #4  
Old 01-04-2006, 04:44 AM
Brandon314159
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Welding of the Modified Intake

Here are some photos of the intake being welded. Nothing fancy as far as pictures go but the finished product pictures are next.

Note: Hot!

BTW if you look in the background you can see how expansive this shop is. In the first picture in the top right corner you can see the end of a crate. Its actually 40 some odd feet long and is housing an IMAX screen soon to go into the Spruce Goose Museum across the highway near McMinnville, OR
Attached Thumbnails
w126 Body 300SD Water/Air Intercooler Project-picture-015.jpg   w126 Body 300SD Water/Air Intercooler Project-picture-016.jpg   w126 Body 300SD Water/Air Intercooler Project-picture-017.jpg   w126 Body 300SD Water/Air Intercooler Project-picture-018.jpg  

Last edited by Brandon314159; 01-04-2006 at 06:26 AM.
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  #5  
Old 01-04-2006, 04:49 AM
Brandon314159
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Finished Intake Pictures

Here are some pictures of the finished intake manifold. I have a slight amount of fine grinding to do inside (got the coarse hogging of the metal done) and I need to reduce the height of that cylinder 1-2 baffle slightly as it would naturally scoop a ton of air into cylinder 1 considering the angle. I may or may not touch this...perhaps just at the very high point to remove the ridge and smooth it out a little. The stock setup pushes a TON of air onto cylinder 1 and that seems to have no problems so....

Ignore the intercooler in the background...its next
Attached Thumbnails
w126 Body 300SD Water/Air Intercooler Project-picture-034.jpg   w126 Body 300SD Water/Air Intercooler Project-picture-035.jpg   w126 Body 300SD Water/Air Intercooler Project-picture-037.jpg   w126 Body 300SD Water/Air Intercooler Project-picture-038.jpg   w126 Body 300SD Water/Air Intercooler Project-picture-040.jpg  

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  #6  
Old 01-04-2006, 04:55 AM
Brandon314159
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The Intercooler Modification- The Beggining

Here are some pictures of the intercooler I started out with. It has a 3inch intake and a 2.5" outlet. I am not totally sure what it came off of but it is stamped with an Audi symbol and is all aluminium. Perhaps it was a light industrial use setup.

Anywho, basically what I needed to do here was modifiy the cooler so that it had tanks on the sides and also modify the 3inch intake due to a inproper angle for hooking up to the turbo. Seeing how it fits in the car is the real fun part.

If anyone knows what that intercooler is off of, please chime in. A size comparison to a more standard Audi intercooler is shown. The core is approximately 11" by 6" and 3.25" thick.
Attached Thumbnails
w126 Body 300SD Water/Air Intercooler Project-picture-006.jpg   w126 Body 300SD Water/Air Intercooler Project-picture-007.jpg   w126 Body 300SD Water/Air Intercooler Project-picture-009.jpg  

Last edited by Brandon314159; 01-04-2006 at 06:29 AM.
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  #7  
Old 01-04-2006, 05:03 AM
Brandon314159
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The Intercooler Modification- The End

Unfortunately I forgot I had the camera in the car so I have no pictures of the process of putting the tanks on however the process is pretty straight forward. Basically you bend up a 5 sided box and weld it to the side of the intercooler. Also you must put in something to pass water through. I installed a quantity of 4 1/2inch pipe threaded ports into the intercooler. Basically two of them are on one side as an intake and two others are on the other side for the outlet.

I decided to use a total of four becuase installing MORE ports later is a much more difficult task and it should give me more even of a flow inside the cooler.

Much thanks to dad for all the TIG work. After watching him I will soon have to try my hand at this process.

The tight cornered 3inch intake on the IC still hasn't be cut off in these pictures however it is soon to go on the list.


BTW Yes the two water inlet/outlet ports are on opposing ends of the IC.
Attached Thumbnails
w126 Body 300SD Water/Air Intercooler Project-picture-042.jpg   w126 Body 300SD Water/Air Intercooler Project-picture-043.jpg   w126 Body 300SD Water/Air Intercooler Project-picture-044.jpg   w126 Body 300SD Water/Air Intercooler Project-picture-046.jpg  
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  #8  
Old 01-04-2006, 07:22 AM
kmaysob's Avatar
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wow nice work! i too would like to learn to tig weld. someday
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  #9  
Old 01-04-2006, 02:33 PM
Brandon314159
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Bump. I think this got stuck on the 2nd page
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  #10  
Old 01-04-2006, 03:05 PM
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I wish I had a TIG and knew how to use it.....or a local friend with one.
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  #11  
Old 01-05-2006, 01:57 PM
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Just remember, we want dyno results or at least 0-60 times before and after this mod.
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green 85 300SD 200K miles "Das Schlepper Frog" With a OM603 TBO360 turbo ( To be intercooled someday )( Kalifornistani emissons )
white 79 300SD 200K'ish miles "Farfegnugen" (RIP - cracked crank)
desert storm primer 63 T-bird "The Undead" (long term hibernation)

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  #12  
Old 01-05-2006, 02:30 PM
Brandon314159
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Quote:
Originally Posted by ConnClark
Just remember, we want dyno results or at least 0-60 times before and after this mod.
My 0-60 times have been posted numerous times elsewhere on the forum and as I stated in the first post I have no way to dyno the car. And even if I did, the pump is already turned up a little so it wouldn't be a stock baseline.

But there are plenty of people around who can take care of that.

Anyway the main purpose and data I plan on getting out of this is the reduction of EGT's. Basically I'll be able to say something along the lines of "water/air intercooling with this size core will give you X temperature drop in EGT's.

Hopefully
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  #13  
Old 01-05-2006, 02:40 PM
ConnClark's Avatar
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Well, I would expect an improvement in your times. I don't care if you tweaked your ALDA you can tweak it again. Since you already have a base line its all good. Your EGTs may not drop a lot, but you can say your trying to save the world from NOx if they do . Kudos to you.
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green 85 300SD 200K miles "Das Schlepper Frog" With a OM603 TBO360 turbo ( To be intercooled someday )( Kalifornistani emissons )
white 79 300SD 200K'ish miles "Farfegnugen" (RIP - cracked crank)
desert storm primer 63 T-bird "The Undead" (long term hibernation)

http://ecomodder.com/forum/fe-graphs/sig692a.png
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  #14  
Old 01-05-2006, 02:45 PM
Brandon314159
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Quote:
Originally Posted by ConnClark
Well, I would expect an improvement in your times. I don't care if you tweaked your ALDA you can tweak it again. Since you already have a base line its all good. Your EGTs may not drop a lot, but you can say your trying to save the world from NOx if they do . Kudos to you.
Heh I guess since you are sorta new to the forum you haven't seen to what extent I have modified my injection pump.

I've INTERNALLY modified it...and thanks to other forum members help I wrote this webpage on how its done: http://brandon.importtransmissionexchange.com/benz_files/full_load.htm

So its not quite as easy as an ALDA adjustment for me. My car is actually turned up...not just adjusted back to spec. Thats why its hard for me to establish a baseline stock HP level.
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  #15  
Old 01-05-2006, 02:51 PM
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Well, In that case. Kudos to you for showing what a kraut boy can do to all the rice boyz.

Nothing shames them more than being beaten by a diesel
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green 85 300SD 200K miles "Das Schlepper Frog" With a OM603 TBO360 turbo ( To be intercooled someday )( Kalifornistani emissons )
white 79 300SD 200K'ish miles "Farfegnugen" (RIP - cracked crank)
desert storm primer 63 T-bird "The Undead" (long term hibernation)

http://ecomodder.com/forum/fe-graphs/sig692a.png
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