Working on some upgrades to the car this year. One thing i needed was a better intercooler. High iat in winter air means summer time was gonna be to much.

So decided to try air water with ability to add ice to the tank. Not 100% sure what i will do for tank setups but do have an idea. Thats next to tackle

First thing i did was cut front end off lol. Even with rad support. Added tube supports



I am twin turbo and due to piping run locations a single in single out cooler wasnt going to be as easy to do. Got an idea to run twin smaller coolers. Gonna try these ebay setups from cxracing. Ppl say they work well just not up to their hp rating so oversize them for your hp goals


These are 16x11x4.5", 3" inlet/outlet. Core size should be good for 1000 hp each

Started mocking up frame to hold these


Using mild steel pipe of various diameters mostly 1/2" and 3/4" for mounts. Fits like a glove behind bumper nose lol

 

Main frame was set so made mounts for twin trans coolers. Oil cooler will be mounted to rad




Then painted it up. Had mounted the hood pin mounts and factory nose supports to top cross bar





Thats it for now! Gonna get an idea where i want to mount the water tank, either in rear seat area or trunk. I wanted to avoid trunk to keep pump distance and lines length down. We shall see

 

Looking good. I vote Truck for a clean install man. Ya the lines will be longer but It will be so much easier to add ice ,etc...

 

Yeah plus weight balance is better.

 

I have one of those same coolers for my trans. Was going to add a second for my air-water intercooler, but I decided i'd rather run a small radiator with a filler so I don't have to have a tank somewhere.

http://www.ebay.com/itm/110969168632?_trksid=p2060353.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT
-- Joe

 

I am likely going to try no heat exchanger for now. See where water temps go on long street drives with no ice in tank.

Ice for track.

If i run both at same time the ambient exchanger is gonna heat up my ice water at the track! But it would keep water at ambient for street driving. So i will have to see.

 

Using cobra pump(s) ? That's what I went with.

-- Joe

 

I dont think its big enough? Most guys are running rule 2000's or similar. Need more flow. Rule is a bilge pump so its not designed for closed systems under light pressures. But there are a few others rated for 5-7 psi pressure and high flow.

 

Most guys shouldn't have ditched physics class. Calculate the rate of absorption based on the surface area of the intercooler(s) and then calculate your flow requirements.

Cobra pump flows 5 GPM.

-- Joe

 

I havent calc'd anything but i do know guys have said they have seen efficiency gains when increasing line size to cooler. So we shall see. I heard those cobra pumps were closer to 3 gpm

 

5 GPM is what I saw when I bought a new one.

Either way, water absorbs heat slowly. you need to balance surface area with flow volume.

The best setups run a tank and two loops. You'll have a smaller heat exchanger on your low flow loop sucking heat, and a larger heat exchanger (radiator) on your higher volume loop expelling heat. A transfer tank in the middle.


-- Joe

 

Got everything somewhat mounted and mocked up. Turbos should arrive today and hopefully be in tonight as long as there are no issues. I modded my ls1 fanshroud to fit tighter and better against the smaller rad i have. Its 27x15.5 compared to stock ls1 31x19.

Last things will be cold side piping. I cant weld aluminum so i will have to have a friend do it. I may make it out of left over steel for now to drive it. Eventually will be aluminum

Next is the water tank and lines. Decided on the typical Rule 2000 pump and fabbed my own 12" cube. Holds about 5.5-6 gallons full. I'll run 4-5 depending what works well enough. Need to pick up some 1" line to coolers then T off into 3/4" for the coolers

 

Tanks in and mounted. Started plumbing lines. Wont be to long before i can test the system.

Turbos are in and car runs. Needs cold side piping from intercooler to tb now

 

Tank and lines done. Gotta finish wiring switch in but theres a quick test. Not shabby! Moves a ton of water




Lines. I heat insulated them around the pan, exhaust and trans tunnel

1" main feeds T off into 3/4" to coolers

 

Welp. Makeshift intake system to get it driving last night. Waiting for my aluminum and proper couplers to come in lol. So far everything works. Car feels good.
Need to do some logs to see how close old tune is with new turbos, but so far 10 psi is spot on. Tried 14-15 i think and itblew the coupler off. Lol

Water system seems to work. Cant hear it in the car at idle so i guess thats good. No idea on iats yet since i have no logger

 

Outstanding work bud!

 

Lookin good. More and more like a race car. What is the end goal for mph and et?.....before going mini-tub.

 

Not really sure. This is likely as far as i ever will go. I would like to see lower 8's at 165, getting as close to 170 as possible but that would be stressing my trans and bottom end i think, plus the car doesnt have safety equipment for that speed anyway. Not sure how long i'd get away with it.. Really like to see 1200-1250 whp dyno to be honest. Should be a monster roll car and if i can get it hooking, a decent dig car too

Did a 35 min drive in stop and go city type driving and a 5-7 min short stop at the store. did 3 small boost pulls and got home. Water tank was 101 deg in 73 deg ambient so it got warm. That was about 3.5 gallons. I could fill it to 5.5. May need to look into an exchanger for long cruises in hot air but need to test it more to find out.

No data on iat yet. I ordered hp tuners now since my friend at the local shop is swapped with work and hasnt been available. May do some low boost passes this weekend at the track. We'll see.

 

Did aluminum tubing up to middle coupler. Gotta have buddy weld bov flange to the other piece. And iat bung.

Car seems to be running decent. Had to mess with startup and some idle tuning. 10-15 psi feels good, really good up to 6600 rpm so far. Previous tune seems to be spot on. Hard to tell until we dyno or track tune. Wideband is giving me some issues so i may need to replace it

 

Looking good Orr. Nice fab work, can't wait to see some results!

 

Replaced wideband and didnanother log. Was able to get some better air fuel data, and it was alot leaner than i expected! 12.8 ish air fuel at 10-12 psi and about same at 18 psi!

So i added 5% fuel and got it back to orginal air fuel 11.6-11.8.

Track testing tonight to see what she will do

 

Some data so far

Did 2 track passes but only logged one.

Ended up ingesting some wires from the horn harness in one turbo and damaged turbo pretty bad lol gotta get a new shaft/impeller

Anyway, 15 psi i think, it went 9.42 at 145 with a lazier 1.41 60'. Last year on 15 it went 9.4's at 145 as well but on a 1.35 60'. And this car is now heavier by a good 50-60 lbs my guess likely closer to 80 lol depending how much water is in the tank. Slightly rich but its a good baseline

Next pass it spun bad. 16.5 psi. Heres the IAT data

Start of pass at the staging lights, air temp was 77 deg. After that 9.5 sec run, it rose to 88. Not bad! Much much cooler than before. I used to see 130-150 on those boost levels. I saw 170's on a 24 psi run. But due to turbo damage unable to attempt 20 psi plus run. Gotta disassemble coolers and turbo to access damage

 

Got some driving time in this weekend. Hot humid day. Water tank started off around 79 deg. Iat were 79 deg at start. Within a half hour of driving and 3 short pulls, rose to 97 deg. I parked it in sun for half hr or so and must have heat soaked. Iat was 111 cruising around. So i stopped for 2 bags of ice. Cooled it to 82 deg lol

Then did a good full second gear pull on 19.5-20 psi and it only saw a few deg iat rise. Very happy with that. I want to track the car this week as it feels so fast at 20 psi i think the new turbos are kicking in

 

Good to hear Orr! I just did my first start and break-in yesterday. I have no leaks or any issue, more tuning today.

 

Crazy, looks like that ice really helps out.
No chance of ice getting in your pump is there?
You are brave cutting all that heh

 

It was trappin 153 on 20.5 lbs so i am kinda happy about that. Think it still slightly rich. I figure alittle leaner and maybe a degree of timing it should match my 8 sec pass on 25 psi. Thats awesome on 4 psi less boost. I got i think a 14 deg rise in temps from 70's to 91 deg. I gotta check the logs but very happy with that. Its hard to chill it that cold, it takes a ton of ice and alot of time cycling the water to bring coolers down to freezing. I dont have the patience for all that lol plus lot of money buying ice

Pump has a screen so it doesnt suck up particles

 

i watched some guys cooling down an x275 car between rounds.... big ol' plastic tub under the trunk of the car, and let it sit there and drain as they added cooler after cooler full of ice into the car's tank. he has an industrial ice machine in his trailer. pretty much melted immediately and drained into the tub under the car. once it cooled enough to keep some ice in there without melting, they closed it up, pulled the tub out from under the car, and dumped it in a better location.
WOW that was alot of ice.

 

Yeah i am never gonna do that haha i'm happy enough at 70-90 iat's. Thats more than enough power for me