[200q20v] intercooler

[mlp]

Date: Sun, 02 Dec 2001 12:43:57 -0800
Bernie Benz <b.m.benz at prodigy.net> wrote:

.....
>The 200-20V ICs have an effective core length of 15", the 5Ks are
13.5",
....
>The open flow CSA I have measured as being 6.2 square inches,
....
>open flow CSA I have measured as being 6.2 square inches,
>twice that of 2" ID inlet piping @ 3.14 sq "

In the FWIW data pile, I believe (courtesy of Bob P.) the UrS4 IC
looks,
works and runs something like this:

Gross exterior Core dimensions:

- @ 9.25" Wide (this is a "cold" flow/ i.e.. cooling face dimension
- @ 11.0" Long "Hot" charge air flow dimension
- @ 3.75" Deep.
- CSA gross internal open face @ 13.5" square (see below.)
- IC's Inlet tube INSIDE diameter @ 54mm/2.1" = surface area (Pi*r^2)
= 3.3" sq.
- IC's Outlet Inside diameter @ 62mm/2.42" = surface area of @ 4.6"
square.

The UrS4/6 IC's gross exterior dimensions manage to encompass within
its 9.25" "height" fifteen (15) rows of "pressurized"  charge air
flow, sandwiched between 16 rows of external air cooling fins.  The
charge air travels the 11" length of the cores height tube length.

Each charge air row contains two (2) internal tubes, measuring @1.5" x
.3" each for a total "CSA" if I'm using Bernie's term correctly, of
approximately 13.5 sq inches.

Each of the internal charge air tubes is filled with its own tiny
internal cooling fins (? turbulators), through which, in stock form
the K24 turbo at peak delivery is supposed to cram @ 227 bhp worth of
air.

If I referencing the same 'measurement' Bernie, the UrS4's 13.5"
square inches of internal flow face vs. the 200TQ's 6.2" square seems
a significant difference.  Is the 200TQ's IC stuffed with internal
cooling fins as well?

If one were to use @1.6 cfm per bhp as a rough rule of thumb
bhp-to-cfm conversion figure, one is looking at stuffing something
like @ 360cfm of atmosphere through the IC at peak power? or do you
folks have a better figure for the required, or desired flow volume?

The IC inlet pipe (hotside charge from the turbo) is relatively
"smaller" i.e. I get @54mm or 2.1" of INSIDE diameter, vs. the IC's
outlet to the throttle body hose, which is @62mm or 2.42" in diameter.

On the other hand I notice the Outlet side has to make a fairly funky
bend, which it looks to me some one may have spent at least a little
time thinking about the short side radius of the turn on the outlet
side.  My guess is that the pinch that's molded into the end tank at
that point isn't just an accident, but was done for some reason of
flow.

> The two cores were combined by first swaging the inlet side
> of each core tube end opened, such that the outlet tubes of
> the first section slip into the inlet tubes of the second ....
> The mating tube plates were then welded together .....
> I have the swaging tool, if any one wants it.

Bernie, what's the "swaging" tool?

Michael