air/water Intercooler

R

Redrider2911

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So I have been procrastinating on getting an intercooler on my rig... Because of the space constraints I can't run a front mount setup so I thought I would do an air/water setup.

I really like how quickly my current system builds pressure do to the short charge piping and I would like to keep that once I integrate an intercooler so I am trying to fit this above the valve covers. My plan is to buy this intercooler from frozen boost http://www.frozenboost.com/air_water-ic/water-to-air-intercoolers-p-214.html?osCsid=1768d7053bc71c4357eaef180cd1b949 then cut off the tanks and make my own that will better fit my application.

For the heat exchanger I plan on just buying another generic 2 row aluminum SBC radiator and mount it under the bed with a Volvo or Taurus electric fan.

Here is a quick drawing of what I have to work with. Let me know your thoughts.

[ame="http://s86.photobucket.com/user/redrider2911/media/Intercooler_zpsntxanq47.png.html"]Intercooler_zpsntxanq47.png Photo by redrider2911 | Photobucket[/ame]
 
I have been doing some discussion with Bell. They suggest at least a 6"x18"x4.5" deep core, a 9"x18"x4.5" core is preferred. That just seems crazy compared to what a lot of the aftermarket cores are "rated" at... It did give me a good idea though. I think I could fit an 8"x18"x4.5" above the valve covers between the turbo and the intake, then make the tanks on the intake side custom with a dual feed setup.
 
Parts showed up on Friday.

[ame="http://s86.photobucket.com/user/redrider2911/media/Willys%20Build/CEB03375-2E29-4D1C-8595-3076A0BFA069_zpselxfst9b.jpg.html"]CEB03375-2E29-4D1C-8595-3076A0BFA069_zpselxfst9b.jpg Photo by redrider2911 | Photobucket[/ame]
 
So I kind of mocked this thing up to see what I am working with. Man this intercooler is a lot bigger once you try to fit it under the hood of a Willys. haha.

[ame="http://s86.photobucket.com/user/redrider2911/media/Willys%20Build/E8733490-5D72-4A93-B1BD-08B13EBBCB9B_zpsnxyz1wmv.jpg.html"]E8733490-5D72-4A93-B1BD-08B13EBBCB9B_zpsnxyz1wmv.jpg Photo by redrider2911 | Photobucket[/ame]

[ame="http://s86.photobucket.com/user/redrider2911/media/Willys%20Build/CC407FA4-57B1-44C3-91D8-0B78F724AC36_zps3atxpljn.jpg.html"]CC407FA4-57B1-44C3-91D8-0B78F724AC36_zps3atxpljn.jpg Photo by redrider2911 | Photobucket[/ame]


Umm. So. I need to figure out how to route the charge air without losing a bunch of efficiency. How much do I need to worry about turbulence here? Or is it kind of just a high pressure area (intercooler, charge pipe, and intake plenum) being forced into a low pressure area (cylinders) and flow velocity isn't such a concern?

This is kind of what quickly came across my mind. Feel free to pick it apart if you have helpful ideas on how I can make this work.

[ame="http://s86.photobucket.com/user/redrider2911/media/Willys%20Build/Intercooler_zpsqfte1rw1.png.html"]Intercooler_zpsqfte1rw1.png Photo by redrider2911 | Photobucket[/ame]

My main worry right now is how the charge air is going to be forced out of the turbo and directly into a "wall" before it makes its way around the left turn. Is this going to be a big issue? I did notice that a lot of air/air intercoolers kind of do the same thing on the end tanks...

Thanks for your input guys,
Kris
 
Ghostman said:
I wouldn't be too concerned with efficiency. Just try to fit it in.
Click to expand...

Well there is a big part of me that is thinking that the huge gain I am going to get from just having an intercooler will outweigh some inefficient flow in the process...

Am I doing something wrong with my photobucket links that they don't show up 100% imbedded?
 
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So I've never messed with the flow simulation in Solidworks so I decided to do a little trial and error today to get some results. I don't exactly know how to properly interpret the data for my use but found it interesting to see less "red" than I expected. Maybe some of you guys more experienced in fluid dynamics can help me out.

There were a lot of options for the analysis but I selected the ones I felt were relevant.

All simulations were ran at 67lb/min on the inlet and atmospheric pressure at the outlet. I know the outlet parameters aren't atmospheric but I didn't know what to put here for the sake of the test.

Velocity.

[ame="http://s86.photobucket.com/user/redrider2911/media/Willys%20Build/Velocity_zpsekrhvav7.png.html"]Velocity_zpsekrhvav7.png Photo by redrider2911 | Photobucket[/ame]

Pressure.

[ame="http://s86.photobucket.com/user/redrider2911/media/Willys%20Build/Pressure_zps6esi9dwr.png.html"]Pressure_zps6esi9dwr.png Photo by redrider2911 | Photobucket[/ame]

Turbulent Energy.

[ame="http://s86.photobucket.com/user/redrider2911/media/Willys%20Build/Turbulence_zpsadmurgh6.png.html"]Turbulence_zpsadmurgh6.png Photo by redrider2911 | Photobucket[/ame]

Stagnation.

[ame="http://s86.photobucket.com/user/redrider2911/media/Willys%20Build/Stagnation_zpscglgfl1l.png.html"]Stagnation_zpscglgfl1l.png Photo by redrider2911 | Photobucket[/ame]
 
Way over thinking this
Also deleting the http:// that pops up with the image thingie will make pictures visible in your thread
 
No turning back now.

8BBCDC77-C1CE-4FCF-B9A4-16348697F220_zpsub6gc5ap.jpg
 
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Thanks for the compliments guys.

Intake side all welded together and tacked to the core. I think it's gonna look pretty cool after I use some scotchbrite to dull the shine.

95C6C45B-553C-4D73-9BDE-7B1D3DDB4D01_zpsyionj9e0.jpg


5EF9BE6A-659A-44F0-B6BA-0293163A8341_zpsunfieutn.jpg
 
Is this for street driving? Do you intend to run ice water through it or engine coolant?

BTW, great idea and awesome fab skills!
 
RockinRam96 said:
Is this for street driving? Do you intend to run ice water through it or engine coolant?

BTW, great idea and awesome fab skills!
Click to expand...

Yes. Street driven. Occasional Towing. Weekend drag strip fun.

I have a 18"x24"x3" 3 core aluminum radiator that will be mounted under the bed with a Taurus electric fan as well as a jerry can converted to a water reservoir that will hang on the outside of the bed on the passenger side.. I'm hoping that the radiator and 5 gallons of water will be enough to keep the intercooler cool on decently long pulls. At the strip I can easily screw the lid off the the jerry can and fill with ice.

My idea for plumbing is Jerry can > CSR style SBC electric water pump > Intercooler > Radiator > back to Jerry can. The pump is rated at 35 gpm open flow.
 
Love the Jerry can idea. If one is not enough easy to add another and will look right at home.
 
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