diesel 300d intercooler
 

Hey Folks,
I'm going to build an intercooler for the 617. Anyone want to help. If anyone helps me considerably than I'll give you one of the finished ones for free.
Thanks
jon
p.s. bgkast? you in?

You talking about making an intake housing with an AWIC inside?

I'm in, on the theory and planning anyway. I want to intercool my W123 300D/617 and eventually the 60x engine I plan to drop in.

Kind of pointless until one makes a trip to Myna Diesel though. Or maybe I'm wrong?

That would be the way to go.

I'll help, just let me know what you need. :)

intercooler
 

Honestly, I don't know anything about intercoolers so I guess the first thing would be to rip one off a volvo and re-engineer it for the 617

-jon

I'm about 2 hours from you, if I can help, let me know.

im about 30 minutes from you. im in pa myself

I guess I am 4-5 hours away, but interested none the less. Is this plan for an air to water IC built into an intake manifold? No plans for an A2A cooler?

I was thinking about A2A with methanol/water injection.

I have access to a Dyno and several race tracks if that is of any help.

http://www.w124performance.com/image...installed2.jpg
Source: http://www.w124performance.com/

Simple, yet effective. This design would allow the user to keep their stock air conditioning condenser and fan.

Can we adapt something like this to a W123?

Page doesn't work.

Yeah, it doesn't work. If you backtrack from that image however you'll find more pics.

I just listed the website to give credit and not piss anyone off.

That thing can't flow well or be too efficient with those few, long tubes. Anyway I don't think there is room in a W123 there.

yeah, and I'm worried that that site might be about to go away.

I tried to back out of the 'images' directory into any kind of index or home page, and got a hoster-page that said someone had just registered the domain-name with them.

Not sure, but that might mean that the guy who originally registered it and put all that great info up there is about to lose the domain....and all that great info is about to disappear.

If that site IS changing hands, someone with broadband might want to do a spider-crawl and grab everything on there....

I only have slow rural-modem here....so I can't do it in any practical sense....

ebay ftw

That setup currently has about the same length of tubing as a stock OM606, yet has a physically larger IC. It works fine for stock or a slightly larger turbo, but not the big Holsets and a maxed out pump.

That is the same location I was thinking of using. You can fit something about 8"x30" IIRC. There just isn't any better place if you keep AC, and want A/A.

You could always copy this set-up...
http://i176.photobucket.com/albums/w...setup002-2.jpg

Not much airflow over the core.

Maybe it's a a/w setup.

Nope. Saab 900 air-air.

You could put a little fan like this to increase airflow taken from this article.

http://us1.webpublications.com.au/st...109459_9mg.jpg

Does just fine- my egt's are low and while I planned to put a inline fan there, the egt's told me it was not needed. It may be needed with the DV's cut and the FLFL removed, but I'm not there yet. Remember my exhaust manifold is process coated.

Flfl? You had Cermakrome OD, Ultra High Heat Insulator ID. done?

Full load fuel limiter. I think the exhaust coating does quite a bit to lower egt's, but since I have no scientific data to back it up I'm only guessing.

I don't see how a coating would lower EGT unless its keeping heat out of the intake...

Rack limiter removal?

Read thru the site and others. It does without question according to those in the know.

yep... so I ought to call it RLR from now on, eh?

Coating would RAISE EGTs since its keeping more heat in the manifold.

Sorry to dig up this old thread. I have a couple of questions. It looks like the turbo connects directly to the intake manifold. Is it possible to re-clock the stock turbo in such a manner as to permit access to the hose connection points on the turbo (air output) and intake. From there, if it will work, it is really just a matter of plumbing, right? I really don't want to have to weld on my intake manifold.

As for the coatings I have heard of coatings on intake bits lowering intake temps (makes sense) but never an exhaust coating lowering exhaust temps.

Yes, loosen the 6 bolts on the back of the compressor housing and it will rotate 360*. The intake has no way of attaching a hose you you will have to cut a lip in the manifold or weld a fitting on it. If you want to attach something to the intake, you will have to remove it either way.

Coating the exhaust does not lower exhaust temperature, it keeps heat in. Keeping it in the manifold makes the turbo work more efficiently with less backpressure.

Here is what I did for my first manifold.

The egt's are not raised- they are kept the same, which allows the gasses to exit the engine more quickly. Here is a good explanation:
If gases are allowed to cool they loose mass which causes them to lose velocity which reduces the scavenging effect. By insulating the exhaust pipe the gases are kept at the highest possible temperature which improves the scavenging effect and reduces underhood temperature.

Interior coatings on exhaust systems are very important, they help the exhaust gas retain its heat and it reduces part temperature, oxidation and corrosion.

My egt's do not get over 1000f unless my speed is over 70mph, and then only if I am accelerating. If I am cruising at 70 mph and "floor it", then around 85 mph do I get over 1100. If I stay at that speed (85), the egt's lower to around 900. If I start from a stand still I'll get high egt's with a full throttle run to 90. The stock turbo(s) inherently generate high egt's at higher rpm's. I'm happy with the set-up for many reasons. Everything is a compromise, and when you raise one variable, you effect many others.