Stock Intercooler Fix
#1
Stock Intercooler Fix
So getting a Power FC has been good and bad. It has made my car run better, eliminated the 3k hesitation, deleted the emissions stuff and automatic warm-up system, and made it idle smoother. On the bad side, I can now see the coolant and intake temps. For this thread, I'm just going to cover the intake temps and what I did to bring it down.
So my set-up is basically stock except for a set of BNR Stage III's, Street port, Fighters Garage intake, and a PFC. Still using the stock intercooler.
So, again, the PFC allows you to see a lot of stuff but my intake temps are what set off the sleepless nights. Why so high? On a regular day just rolling along the temps seemed to stay at 73C (163F) which in my mind is detonation just waiting to happen. So I asked a few people on this site if this was normal and all said no..."That's really high". I decided to take a look up front to see just what the stock intercooler ducting looked like. I couldn't see it. So I got a towel and laid on the ground...there it was...way up there^^^. No way was any air getting to it especially with my aftermarket front clip. Time to fix the air flow. Here's what I did....
Stock duct which terminated behind the fiberglass crash-bar. In my car, this could not be seen with the front clip installed.
So fabrication of the ducting starts...
Fitment first then more rivets..
A top is added to complete the duct extension.
Next I have to trim the fiberglass crash-bar to accommodate the duct.
Cutting complete. This is the bottom of the crash bar.
Now close to the finished product with the crash-bar reinstalled..
Finally, the front clip reinstalled...(ignore the damage to the front. I know it's there).
Now for the top side hole...
Done.
So what is the result temp wise?
Before= 73C (163F)
After= 47C (117F)
Temps verified using the PFC before and after with the "fast acting" after-market temp sensor.
Hope this helps others in a quest for lower temps on a budget.
Steve.
So my set-up is basically stock except for a set of BNR Stage III's, Street port, Fighters Garage intake, and a PFC. Still using the stock intercooler.
So, again, the PFC allows you to see a lot of stuff but my intake temps are what set off the sleepless nights. Why so high? On a regular day just rolling along the temps seemed to stay at 73C (163F) which in my mind is detonation just waiting to happen. So I asked a few people on this site if this was normal and all said no..."That's really high". I decided to take a look up front to see just what the stock intercooler ducting looked like. I couldn't see it. So I got a towel and laid on the ground...there it was...way up there^^^. No way was any air getting to it especially with my aftermarket front clip. Time to fix the air flow. Here's what I did....
Stock duct which terminated behind the fiberglass crash-bar. In my car, this could not be seen with the front clip installed.
So fabrication of the ducting starts...
Fitment first then more rivets..
A top is added to complete the duct extension.
Next I have to trim the fiberglass crash-bar to accommodate the duct.
Cutting complete. This is the bottom of the crash bar.
Now close to the finished product with the crash-bar reinstalled..
Finally, the front clip reinstalled...(ignore the damage to the front. I know it's there).
Now for the top side hole...
Done.
So what is the result temp wise?
Before= 73C (163F)
After= 47C (117F)
Temps verified using the PFC before and after with the "fast acting" after-market temp sensor.
Hope this helps others in a quest for lower temps on a budget.
Steve.
#2
AponOUT!?
iTrader: (31)
i've done the same thing with my stock mount custom IC, except i used some carbon fiber sheet to extend the duct.
oh and btw, lower temps or not, if you plan on pushing more boost don't even bother keeping the stock intercooler. the plastic end tanks are prone to crack/leak even if you're not pushing more boost.
modified pettit c.c. III duct:
oh and btw, lower temps or not, if you plan on pushing more boost don't even bother keeping the stock intercooler. the plastic end tanks are prone to crack/leak even if you're not pushing more boost.
modified pettit c.c. III duct:
#7
Urban Combat Vet
iTrader: (16)
Budget is a relative term. And I say this having stuck with the OEM IC for several years.
I appreciate what you've done. I also did something similar. I just didn't have a PFC at the time to see the results.
But it seems like your also reducing flow to the radiator by the same amount your increasing it to the IC. IMHO, one of them (radiator or IC) eventually has to become more efficient just to maintain status quo because the nose is still getting a finite amount of air.
Getting back to budget and intake temps, it might be easier to install a simple basic AI system to to compensate for the stock IC inefficiencies and bring IATs down... more than a duct extension, but less than a larger quality SMIC.
I appreciate what you've done. I also did something similar. I just didn't have a PFC at the time to see the results.
But it seems like your also reducing flow to the radiator by the same amount your increasing it to the IC. IMHO, one of them (radiator or IC) eventually has to become more efficient just to maintain status quo because the nose is still getting a finite amount of air.
Getting back to budget and intake temps, it might be easier to install a simple basic AI system to to compensate for the stock IC inefficiencies and bring IATs down... more than a duct extension, but less than a larger quality SMIC.
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#8
Sgtblue,
As an engineer I appreciate your input and the suggestion of an AI system which we all know the benefits of, however, this is a thread on a budget. I just wanted to report that with my mods I achieved a 46F temp difference for $11 worth of materials. Take it for what it’s worth.
Steve.
As an engineer I appreciate your input and the suggestion of an AI system which we all know the benefits of, however, this is a thread on a budget. I just wanted to report that with my mods I achieved a 46F temp difference for $11 worth of materials. Take it for what it’s worth.
Steve.
#11
Rotary Freak
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I did the exact same thing to my ebay SMIC last weekend. I was going to post some pics in hopes of being the first but apparently others are just as smart
Anyway my results were positive as well. I went from 25 degree above ambient to 15degree above ambient. These results were noticed on my pfc and also using a fast air intake sensor.
My next project is to get cool air to the filters instead of hot engine air.
Anyway my results were positive as well. I went from 25 degree above ambient to 15degree above ambient. These results were noticed on my pfc and also using a fast air intake sensor.
My next project is to get cool air to the filters instead of hot engine air.
#12
RX-7 Bad Ass
iTrader: (55)
Good job, Steve!
This also goes to show how critical ducting is to a stock mount intercooler. I've seen PLENTY of Ebay stock mounts tossed in with no ducting, guys thinking "it'll be just fine". Nope, it won't.
Steve, did you have the stock duct that goes from the intercooler duct to the airbox installed previously? Or was that hole just open?
Dale
This also goes to show how critical ducting is to a stock mount intercooler. I've seen PLENTY of Ebay stock mounts tossed in with no ducting, guys thinking "it'll be just fine". Nope, it won't.
Steve, did you have the stock duct that goes from the intercooler duct to the airbox installed previously? Or was that hole just open?
Dale
#14
Eats, Sleeps, Dreams Rotary
iTrader: (14)
However, I did have to remove it during the summer because my coolant temperatures started climbing above what they used to because of the radiator obstruction. I would monitor these closely.
A better test of performance would be recording temperatures after driving the car very hard for 15 minutes. Though, I think that this could be risky. When my intake temperatures climb above 45C I stay off the boost. 73C would scare me silly.
As others have mentioned, I would go with water injection. With a little creativity, it is possible to put a simple system together for a few hundred bucks these days.
#15
That stock duct was deleted before I got the car. The previous owner installed some type of aftermarket intake which I ditched for the Fighters Garage intake. Gotta say though, I'm pretty happy with the results of this little project. My wife started laughing when I told her I had to go to Home Depot for some car parts.
Steve
#16
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Just a bit more info. My car water temps has never climbed a degree with this mod. My fans come on at 85 and the pfc has not seen 86 once. This is just cruising around the streets, so highway, and stop and go.
I do have an aftermarket rad though so that too could help a bit.
I do have an aftermarket rad though so that too could help a bit.
#20
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haha, and I am thinking what a nice idea!
I made it yesterday for just my better feeling and wow... i don´t have a PFC but your numbers really makes me happy. this thing will work.
my modify
I made it yesterday for just my better feeling and wow... i don´t have a PFC but your numbers really makes me happy. this thing will work.
my modify
#21
Urban Combat Vet
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Good to see you posting Metan. Jak se mas?
But even though this is an oldie, low budget mod, I have doubts that the OP's results are repeatable. No mention of the conditions before and after intake temps were taken, engine temps, forward speed, boost conditions, ambient temps or anything else. Re-reading his reply on whether or not the hole at the top of the duct had previously been plugged and couldn't really tell what the answer was. If it was open previously I'm with moconnor, much of the temp drop might be due to just plugging that.
But even though this is an oldie, low budget mod, I have doubts that the OP's results are repeatable. No mention of the conditions before and after intake temps were taken, engine temps, forward speed, boost conditions, ambient temps or anything else. Re-reading his reply on whether or not the hole at the top of the duct had previously been plugged and couldn't really tell what the answer was. If it was open previously I'm with moconnor, much of the temp drop might be due to just plugging that.
#22
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ahoj, mam se dobře, díky
I am with you about covering the hole in the top, (this is definitely the whole point of this mod, but still, extend ducting makes sense to me.)
I still use a stock airbox with K&N. So this is a bonus for airbox too. I think it is
On the other hand, it might be better to cover the top hole and let the airbox to suck in air without a transition piece of plastic.
without PFC, I am not able to test and measure: (
I am with you about covering the hole in the top, (this is definitely the whole point of this mod, but still, extend ducting makes sense to me.)
I still use a stock airbox with K&N. So this is a bonus for airbox too. I think it is
On the other hand, it might be better to cover the top hole and let the airbox to suck in air without a transition piece of plastic.
without PFC, I am not able to test and measure: (
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