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Thread: My A/W intercooler build

  1. #51

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    Quote Originally Posted by Sick 660r View Post
    Anyone use something like this to insulate the intercooler? I have a buch left over from insulating the garage doors. Trying to avoid spending the money on the DEI insulation sheets.

    http://m.homedepot.com/p/Reflectix-1...025/100012574/
    I used that same stuff for my CAI. Seems to help some looking at the data logs. It won't take rough handling, clamping/squeezing, etc as it will crush the air pockets defeating some of the insulation properties. It seems to hold up to heat pretty well, but open flames not at all. That close to the headers would keep a close eye on it for awhile to see how it holds up. I also used this stuff http://www.summitracing.com/parts/dei-010462 on my intake and it is holding up really well. Don't have any data to see how much it helped if any but the manifold does seem to stay cooler to touch than it used to. Not very scientific
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  2. #52

    Duner's Avatar
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    The stuff I used for my 4.7 intercooler looked similar - but was made from shredded clothing with foil on each side. No plastic to melt.
    Duner
    4.7 Turbocharged CC in white - 12's
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  3. #53
    Sick 660r's Avatar
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    I may just but the bullet and buy this. I can also add a heat shield under the intercooler.

    https://www.designengineering.com//c...hesive-backing

    Had the brace and master cylinder adaptor powder coated today. It's an odd looking brace but gets the job done! I limited the intercooler lines in the engine bay to 36" because that's the length of the DEI wrap. One line is a little tight but making the fitting 120* vs 90* will take care of it. Im one fitting short anyways so it works out.





    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  4. #54
    Sick 660r's Avatar
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    Wired up the fans and pump to a switch in the cab that I used to use for data logging. I'll leave it like this until I figure out how to control it with megasquirt.

    Fans move some air!


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  5. #55

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    That sounds like it will move some air. Will any air draw across the heat exchanger without the fans on?
    1999 CC R/T
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  6. #56
    Sick 660r's Avatar
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    Very little if any. I didn't have room up front. I'll have to log the intake temps to see how I want to control the fans. Hopefully I only need two.


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  7. #57
    Sick 660r's Avatar
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    I now have MS controlling the intercooler system. I used one of the six mid current PWM grounding outputs to ground the relay. It will come on whenever the temp is above 160. I believe it may still run with the engine off and key on. I will most likely have to add a 0 rpm column and set the values to zero. I wasn't able to figure out how below/above duty works.



    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  8. #58

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    Very nice setup. I was just looking at frozen boosts site.

  9. #59
    Sick 660r's Avatar
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    Yesterday was the third time I blew the discharge tube off the Paxton outlet. I never used to have the problem so I'm assuming the restriction due to the intercooler has increased pressure enough to pop it off. I'm going to pull the SC and weld a small bead around the edge of the outlet to keep the clamp on.


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  10. #60


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    Lol I remember the first time I blew mine. Scared the shit out of me cause I had no idea wtf happened. Blew the clamp off the air hat and it had even turned the air hat from the pressure. Got it all fixed though. Haven't done any 16lb pulls yet but holds good to 12-13. What are you pushing for boost? I'm likely going to take mine out again and go with vbands.
    Chad
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  11. #61
    Sick 660r's Avatar
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    Quote Originally Posted by 99blackrt View Post
    Lol I remember the first time I blew mine. Scared the shit out of me cause I had no idea wtf happened. Blew the clamp off the air hat and it had even turned the air hat from the pressure. Got it all fixed though. Haven't done any 16lb pulls yet but holds good to 12-13. What are you pushing for boost? I'm likely going to take mine out again and go with vbands.
    I've seen 13 regularly but I think I hit 15 yesterday. I didn't datalog but auto tune showed 6700 rpm and 202 kpa so I guess technically 14.7 psi. I'm trying to avoid anything rigid.


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  12. #62
    Sick 660r's Avatar
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    Should fix the issue



    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  13. #63


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    I can't believe your wife let you weld in the kitchen

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    Quote Originally Posted by krs1r/t View Post
    I can't believe your wife let you weld in the kitchen
    I think he isn't married and is his girlfriend, pretty sure if it was wife, he would not be doing anything in the kitchen other than cooking and cleaning.....
    This signature has been deleted thanks to photobucket!

  15. #65
    Sick 660r's Avatar
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    I'm not married lol


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  16. #66

    Friggin' R/T's Avatar
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    Quote Originally Posted by Sick 660r View Post
    Should fix the issue

    I'm surprised there wasn't already some sort of lip on the edge of the discharge. Is blowing the tube off a common problem?

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  17. #67
    Sick 660r's Avatar
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    I don't know why Paxton didn't have one. I don't know of many blowing it off unless they use basic worm clamps. T bolt clamps usually fix the problem. I'm really curious what the pressure is on the hot side of the intercooler. I was going to weld a bung in the hot side to see the temp difference. I may do it now and I can also record pressure using the stock map sensor but it's probably more than the 2 bar can handle.


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  18. #68


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    Quote Originally Posted by Friggin' R/T View Post
    I'm surprised there wasn't already some sort of lip on the edge of the discharge. Is blowing the tube off a common problem?
    Eventually, I blew mine off a few times. I blame the stock heads for the restriction though, was up around 10psi.

  19. #69
    Sick 660r's Avatar
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    Hose clamps or t bolt clamps?


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  20. #70


    6speedrt's Avatar
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    2 Hose clamps per side, everything was stock with the kit for the most part except the intake. Hose clamps suck, so I bought t bolt clamps but never ran it. I don't own the supercharger any more.

    Edit: Forgot actually I did run it, just not at the strip. Danno and I took it to California and on the way home took it up to around 12psi several times and the t clamps held. Soon after it started smoking out the valve covers and been on jackstands ever since.

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