From knowing nothing to having a Thunderbird supercharger on an m20b27i

[The Dark Side of Will]

Look at what Mustang Cobra and 3800 Supercharged guys are running for their HEX's... That should give your a good idea of what it takes to handle what power level.

[Q5Quint]

Oh shit!/Oh boy!

.....Then I realized I'll likely get a decent bit of power when I seal that leak up.

More to come...

Heck yes- I did the air compressor leakdown test on my charge pipes when I had the turbo- found all kinds of leaks just around the silicon connections etc. Some hairspray and some wiggling and tightening got them fixed. There was also the 1/4" threaded hole in the bottom of the intercooler that I forgot to screw a bolt into..... I am sure I got 1psi more or atleast some better boost response and lower turbine speeds from that.

For the folks who dont believe in water to air.... just do some math.

a 8"x4"x3/4" water-water heat exchanger will do about 22k btu for water to water..... so for the air-water the 14.5"x5"x4.5" makes sense.

http://forums.tdiclub.com/showthread.php?t=378896

Those guys have some good numbers but it does look like the water cooler unit in front is big as heck... like a/c condenser size.

I would leave everything stock and see if you can nab some transmission coolers off cars at the pick and pull for $5 or something. There is plenty of space behind the grill up there for something small like that without having to move things around.


Proper sizing would be figure out how many BTU that you need dissapate between certain cfm flow rates, figure out the surface area of cooler inside the intake you need, figure out that it is large enough to not block the flow of your intake, then size your external cooling radiator to match a certain % of that btu load. Making it too big wont hurt, since it will just be at ambient temp even if you were at WOT 24/7, but then it and the ex changer in the car might be unreasonably large. Maybe sizing for 75% would be normal, and 100% 'race' or something like that.



From what I can tell though that size difference isnt that big as you might think, since you can fit a lot of surface area into an inch of cooler.

[QUOTE]13.5"x 4"x 3.5" - 350 CFM, 350 HP
14.5"x 5"x 4.5" - 550 CFM, 600 HP
15"x 6.5"x 6" - 1200 CFM, 1200 HP[QUOTE][QUOTE]

Edit- after looking at some of this I might go the water route as well. No valence cutting or getting rid of headlights/brakes/condensors etc. The savings in tube/silicone plus time makes it worth it.

these are $35 for a 5x12x3/4" http://www.jegs.com/i/Flex-a-lite/40...oductId=756324

You could try one and if it wasnt enough add in a 2nd.

edit edit: even the $1300 tcd kit seems to use two small external coolers. http://turbochargingdynamics.com/?wp...y=intercoolers
no fans!

[Ether-D]

Oh shit!/Oh boy!

So I decided to do do my intercooler plumbing while I have the hood off. I hooked up the heater hoses to my intake input/output nipples and ran them around the battery and to the front corner of the bay to where I'm gonna put the reservoir. Then I thought to myself "I should blow on one of these hoses and feel air come out of the other one." and it did. Then I thought "I'll plug up one of them and blow on the other and I should feel the pressure build up" but it didn't. It just blew right into the intake manifold somehow. And I was all "Fuck! Now I can't hook up my pump and shit because I clearly have a huge leak.". Then I realized that I must have been loosing quite a bit of my forced air through that hole. Then I realized I'll likely get a decent bit of power when I seal that leak up.

More to come...

[Ether-D]

I'm going to say the dog shit is on the left.

We have a winner.

See how thin the metal is at the eccentric end? To the left of the eccentric, the material is about half of the thickness of the oe and the Febi. Middle is the Febi updated one, it has more material to the right of the eccentric. And the far right one is the OE BMW one. See how it's a bit thinner on the right side of the eccentric?

I have 12 of the oe bmw ones in my car now.

[FLG]

Middle.

Sent from my SCH-I545 using Tapatalk 2

[LJ851]

I'm going to say the dog shit is on the left.

[Ether-D]

One of them is OE bmw, one is the redesign by Febi, and one is an aftermarket piece of dog shit.

[Ether-D]

Rockers and such...

So I replaced all 12 of my rockers today. There is a reason. They were all some kind of aftermarket rockers that I took off of a very fresh AMC head that I got at the pull a part. Long story short, the new AMC head was murdered by the installer. He used a sledge hammer to beat the rocker shafts in to submission. Irrrrrrregardless, I used the nice brand new rockers on the head that I rebuilt for the yard motor. Then I broke this one last week and I decided to do a comparison of the ones I have. So, here's a pic for posterity. Does anyone want to guess which type I broke?

[Ether-D]

Let me preface this by saying I've never tried this before, but I don't see any way you could possibly, physically, within the laws of science, use an A/C condenser as an IC. The lines running in to a condenser are 1/2" and designed to carry liquid, not gas. Most ICs have 2" inlets, sometimes 3". You cannot physically force enough air through a 1/2" condenser to make your motor run, it's far too restrictive. How big is the outlet on you SC? How could you possibly neck it down to 1/2"?

You just don't know exactly what I'm doing. Look up "water to air intercooler". Then put a shit load of poetic license on it and that's what I'm attempting.

[Ether-D]

like this?

http://forums.vwvortex.com/showthrea...rcooler-set-up

No, but whatever I do will have to be some crazy thing made of jy parts.

[CorvallisBMW]

Let me preface this by saying I've never tried this before, but I don't see any way you could possibly, physically, within the laws of science, use an A/C condenser as an IC. The lines running in to a condenser are 1/2" and designed to carry liquid, not gas. Most ICs have 2" inlets, sometimes 3". You cannot physically force enough air through a 1/2" condenser to make your motor run, it's far too restrictive. How big is the outlet on you SC? How could you possibly neck it down to 1/2"?

[Q5Quint]

like this?

http://forums.vwvortex.com/showthread.php?5426692-Air-to-Water-intercooler-set-up

[Ether-D]

AC condensers are designed to cool gas, not liquid. A heat exchanger designed for liquid may be more efficient. Since you're on a budget, maybe a junkyard/craigslist radiator from a small car?

Yeah, I'm just gonna start out with the computer radiator (koolance) and see what it does. Then upgrade if needed. The a/c condenser is just bigger than the Koolance one.

[Ether-D]

Now I have to use the computer fans just to prove that they'll work. Damn youuuuuuu!!!!!

[Victell]

AC condensers are designed to cool gas, not liquid. A heat exchanger designed for liquid may be more efficient. Since you're on a budget, maybe a junkyard/craigslist radiator from a small car?