[s-cars] 26x8x3.5 FMIC mock up, why not go with the stock one

[Trevor Frank]

Oops, right except top down, like that cross section.

-----Original Message-----
From: Ray Tomlinson [mailto:ray at s-cars.org] 
Sent: Monday, September 13, 2004 12:48 PM
To: Trevor Frank; James Murray (QB/EMC); Scar
Subject: RE: [s-cars] 26x8x3.5 FMIC mock up, why not go with the stock
one

Trevor et al,

The vertical core bar&plate not only offers less pressure drop over the
stock IC, but also increases the number of charge cores from 17 to over
30.
By comparison, a tube & fin cross-flow measuring 23"x10" offers only 21
charge cores.  Thus, cross-section alone does not determine an IC's
efficiency.  At 750cfm, my vertical FMIC is both small and more
efficient
than the stock IC.

After 2 hours on the dyno, my inlet temps never rose above 170F, and my
TB
temps dropped to within 3-7F of ambient (84F day), and that's with (1)
40mph
fan on the front of the car.  Before the FMIC, my inlet temps were
between
250-280F, and TB temps reduced to no less than 150F.

There are disadvantages.  My FMIC weighs about 16lbs, and I no longer
have
the "support" of a euro bumper core.  But, I digress.


Ray

-----Original Message-----
From: s-car-list-bounces at audifans.com
[mailto:s-car-list-bounces at audifans.com]On Behalf Of Trevor Frank
Sent: Monday, September 13, 2004 2:47 PM
To: James Murray (QB/EMC); Scar
Subject: RE: [s-cars] 26x8x3.5 FMIC mock up, why not go with the stock
one



Honestly why bother?
Put all these constraints on the intercooler until you get to the point
where the stock one is best.  I think that the stock core has nearly the
same cross section but is shorter, this means that it will not cool as
much but also that it doesn't have the pressure drop, so you won't have
to push the turbo so much to make boost, so you wont have such high
inlet temperature.  Inefficiency breeds inefficiency.

  It would be interesting to custom tune a car with a stock intercooler
and see if there is any real advantage to such a small core.

With good programming I have found that there is little advantage to my
big core, honestly if you are not worried about adaptive programming on
hot day's, like you are at a race and want every last hp you have.

To sum it up, to do anything takes time, if you are not going to do it
right then why bother.

It might be an interesting idea to look at is as ROI.  If 2k works some,
and 1k doesn't work at all then 1k is pretty expensive.

-----Original Message-----
From: s-car-list-bounces at audifans.com
[mailto:s-car-list-bounces at audifans.com] On Behalf Of James Murray
(QB/EMC)
Sent: Friday, September 10, 2004 1:54 PM
To: Scar
Subject: [s-cars] 26x8x3.5 FMIC mock up

For anyone interested in doing a FMIC without modifying the bumper,
here's the space you have to work with...

I wanted to see what the 26x8x3.5 Intercooler I saw on e-bay would look
like so I made a cardboard mock-up, and sure enough it's just a tad too
big, it could fit but I'd have to relocate the oil line in front of the
A/C core and it would be right up against the A/C core (no air flow).

I measured the usuable space that you would have assuming you would not
cut into the bumper:

Smallest space on either side from A/C core to bumper is 3.5 inches but
that assumes moving the oil line in front, otheriwise 3 inches is tops.
In the middle of the bumper, because of the curve, you have 5 inches
tops.

>From the top (underneath) of the rebar (bumper core) to the bottom of
the bumper cover you have at max 7 inches (assuming you don't put the
Intercooler Core behind the bumper).

>From the top of the bumper to the bottom of the bumper core you have 5
inches (so the core is about 5 inches thick) vertically.

So a 25x8x2.7 Intercooler would work better than the mock up I made, but
you would still have to have about 2 inches hidden behind the bumper
core..

Ideally for optimal flow you would need a core that was 25x5x3 that way
you could mount it underneath the rebar (not behind it) and gain maximal
air flow. You would have more room for a thicker core actually...
Here are some pictures:
http://forums.audiworld.com/s4s6/msgs/35209.phtml
although I have to bear in mind the surface area of the original IC is
10.25x8.75 = 91.87 (I didn't measure how thick it was...) while if I was
to go with 25x5=125 core I haven't gained all that much in cooling
surface area, but of course I would gain considerably in cooling from
better air flow...
Cheers, /James "still undecided on FMIC" Murray...
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