Installing an Air/Water intercooler
 

Installing an Air/Water intercooler will be my next project. I finished installing a boost gauge and pyrometer today so I can get some baseline measurements before I put in the intercooler. I am using a generic ebay air/water unit that I got for $125, and a Honda Goldwing radiator to cool the water. After the intercooler is installed I plan to turn up the full load setting on the injection pump, and turn up the boost to get boost and EGT back to the levels I have before intercooling.

Pictures are the ebay intercooler and the radiator test fitting. Hood will close with a slight shave of the rear of the grill to clear the cap.

Excellent! I've almost bought one of those intercoolers several times. I can't wait to see how you get it plumbed. I like the motor cycle radiator idea. I just got my a/c working so I don't think I'll be so willing to ditch the condensor.

Here is where the intercooler will be installed:

Are you going to modify the intake manifold any?

I got a spare manifold off of ebay that I will have a 2.5 inch fitting welded to.

I was thinking of fitting one of these in place of the crossover pipe in a 603 -

http://www.cynikal.net/~mike/celica_first_photos/source/5.html

Fit the radiator ahead of a front wheel similar to where a 300SDL has the oil cooler.

Sixto
93 300SD

Better pic -

http://www.cynikal.net/~mike/celica_first_photos/source/8.html

Sixto
93 300SD

Is it possible to use the refrigerant line between the evaporator and compressor to cool the IC or IC radiator? Seems like on a day hot enough to warrant AC you can use the wasted 'coolness' to help the IC.

Sixto
93 300SD

You would loose much more power running the A/C compressor than could be gained from intercooling. The F-150 Lightning prototype tried that....

Agreed, but when you have the AC on anyway? Isn't that 364 days a year in Houston and Atlanta? When it's cool enough to not use AC, it's cool enough to not augment the IC.

Sixto
93 300SD

The problem with these cars is most intercooler spots are taken up by the AC condenser. It is easier to find a spot for a small radiator though than a air/air intercooler. My Air/water radiator resides where the AC would be though.

Progress so far: Not much. I have ordered all of the components. Now I play the waiting game. Did some painting on the radiator yesterday though:

Update:

I have found all of the parts that I will need to complete the system, however I still need to have my spare intake manifold modified. I made up some brackets to mount the radiator today and mocked up the system. Take a look:

I have decided on a different orientation of the intercooler to simplify the piping system. The compressor will now hook directly to the intercooler through a 90 degree elbow. The outlet will hook to the modified intake manifold through a 8 inch long 2.5 inch dia aluminum pipe with a 45 degree bend in the middle. unfortunately now I need to buy new silicone fittings. It's hard to get much work on the setup done when it gets dark at 4:30. :(

It's pretty different from the approach I'll be using. But, my plan will stay under wraps until I'm done... :rolleyes:

Has anyone ever tried to use a scirocco radiator itself as an intercooler? seal off the cap neck and (maybe use a NEW rad) and flow air thru it..