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  #1  
Old 10-20-2006, 01:48 AM
bgkast's Avatar
Rollin' on 16s
 
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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.

Attached Thumbnails
Installing an Air/Water intercooler-intercooler.jpg   Installing an Air/Water intercooler-icrad.jpg  
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1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver

1982 300SD - 232K miles - Wife's Daily Driver

1986 560SL - Wife's red speed machine
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  #2  
Old 10-20-2006, 02:35 AM
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Location: Norman, Oklahoma
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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.
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1984 300D 225K
1985 300D Donor body
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1980 300SD 311K My New Baby.
1979 BMW 633csi 62K+++? Dead odo
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  #3  
Old 10-20-2006, 02:51 AM
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Here is where the intercooler will be installed:
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Installing an Air/Water intercooler-mercedes-intercooler-size.jpg  
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1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver

1982 300SD - 232K miles - Wife's Daily Driver

1986 560SL - Wife's red speed machine
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  #4  
Old 10-20-2006, 02:54 AM
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Are you going to modify the intake manifold any?
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1984 300D 225K
1985 300D Donor body
1985 300D Turbo 165K. Totaled. Donor Engine. It runs!!!
1980 300SD 311K My New Baby.
1979 BMW 633csi 62K+++? Dead odo
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  #5  
Old 10-20-2006, 03:27 AM
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I got a spare manifold off of ebay that I will have a 2.5 inch fitting welded to.
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1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver

1982 300SD - 232K miles - Wife's Daily Driver

1986 560SL - Wife's red speed machine
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  #6  
Old 10-20-2006, 02:42 PM
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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
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  #7  
Old 10-20-2006, 02:44 PM
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Better pic -

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

Sixto
93 300SD
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  #8  
Old 10-21-2006, 07:00 PM
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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
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  #9  
Old 10-21-2006, 07:05 PM
ForcedInduction
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You would loose much more power running the A/C compressor than could be gained from intercooling. The F-150 Lightning prototype tried that....
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  #10  
Old 10-21-2006, 07:08 PM
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smoke gets in your eyes
 
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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
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  #11  
Old 10-21-2006, 08:02 PM
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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:
Attached Thumbnails
Installing an Air/Water intercooler-dsc00934.jpg  
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1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver

1982 300SD - 232K miles - Wife's Daily Driver

1986 560SL - Wife's red speed machine
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  #12  
Old 11-01-2006, 11:27 PM
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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:
Attached Thumbnails
Installing an Air/Water intercooler-ic1.jpg   Installing an Air/Water intercooler-ic2.jpg  
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1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver

1982 300SD - 232K miles - Wife's Daily Driver

1986 560SL - Wife's red speed machine
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  #13  
Old 11-10-2006, 12:57 AM
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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.
Attached Thumbnails
Installing an Air/Water intercooler-icnew.jpg  
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1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver

1982 300SD - 232K miles - Wife's Daily Driver

1986 560SL - Wife's red speed machine
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  #14  
Old 11-10-2006, 01:04 AM
ForcedInduction
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It's pretty different from the approach I'll be using. But, my plan will stay under wraps until I'm done...
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  #15  
Old 11-10-2006, 02:33 AM
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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..

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