Chargecoolers!

[thetyrant]

Ok im in the process of buiding up another turbo kit and this time i want to run a chargecooler water/air setup to help keep intake temps down on track, the air/air IC i had on my previous Sp240 turbo kit was ok on road but started to struggle on track hence wanting to go water/air this time.

Ive been doing some hunting around looking at various options and also watched SpyderLee's cheap vs expensive testing video which was interesting as well, however  im a bit wary of the cheap ebay chargecoolers due to poor designs on some but they are an option, barrel coolers work well but i think getting a big enough/good one will be expensive.

So im more interested in looking at what cars have them as OEM fitment and if they could be made to work on our cars, so far there a a couple of potentials ive found as below and all available for around £100 used or sometimes even less!, not that much for new pattern ones either.

First one is from Jaguar XF and some Rangerovers i think and the most likely candidate so far, only thing i dont like is the plastic end tanks which i know are not so durable as all alloy, however running low boost levels im planning they should be ok i, pic below....

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Another which i think might work is one from a BM F10 550i and being all alloy is a bonus over the plastic tanks on above, however inlet/outlet position isnt as nice for where im thinking of mounting it but still possible, pic below of the Indicatorless wonder one, they do and left hand and right hand version as the twin turbo on 550i has 1 for each turbo, should be plenty of capacity for a 1zz

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Mounting wise i would like to either fit where i had the Air/Air ic on Sp240 which is on front of gearbox, or if not enough room for these it could go around where the stock airbox is, i dont want to move the battery if i can help it either.

Anyhwos just curious as to what others is CC are using and how they find intake temps especially if going on track.

Discuss

[m1tch]

I think Lee ran a cheap ebay special charge cooler on his - out performed the barrel charge cooler he had on there before.

Maybe have a look at some of the Lotus charge coolers as they need to be compact to fit into a small space as well.

[thetyrant]

I think Lee ran a cheap ebay special charge cooler on his - out performed the barrel charge cooler he had on there before.

Maybe have a look at some of the Lotus charge coolers as they need to be compact to fit into a small space as well.

Thats right although i didnt see the actual testing of the old barrel cooler on the car and bench test wasnt ideal imo, also i didnt think the ebay one worked that well on car as with a few hard pulls it was soon upto 50degrees intake and think on track would be more still.

Lotus coolers have the Lotus tax unfortunately and they are generally fitted in a places we dont have, as in above engine or to the side where this is more space on the Lotus, will keep an eye out though.

[Nvy]

All kinds of merc, bmw and VW air to water coolers are available. If I had the time, equipment and skill would go for 2x VW coolers with choped off flange and weld them together.

Something like this - 362370140437 on ebay. Other than that just go for some ebay special and see how you get on. All of coolers on the market are made the same, bar and plate or w/e is that. Some of them just have more fins inside to dissipate more heat.

[shnazzle]

I can NOT recommend any intercooler that has the crimped end tanks. Go for fully welded only.
There's plenty out there.

[thetyrant]

All kinds of merc, Indicatorless wonder and VW air to water coolers are available. If I had the time, equipment and skill would go for 2x VW coolers with choped off flange and weld them together.

Something like this - 362370140437 on ebay. Other than that just go for some ebay special and see how you get on. All of coolers on the market are made the same, bar and plate or w/e is that. Some of them just have more fins inside to dissipate more heat.

No way im going to be cutting of flanges and welding coolers but each to their own, also the cheap ebay chargecoolers often have poor core design actually more suited as air2 air rather than air2water so trying to avoid that, going for a oem fitment should mean proper design i hope

[thetyrant]

I can NOT recommend any intercooler that has the crimped end tanks. Go for fully welded only.
There's plenty out there.

Its not ideal i know, have you experience of them failing ?   most of us have crimped tank coolant radiators and they last pretty well but i understand crimped tank intercoolers are not the same, i guess the varying pressures unlike pretty constant you get with coolant rads doesnt help, i would of thought as long as they mounted correctly to avoid strain on tanks from hoses etc and the pressures are kept low they should last ok.

Reading on the Jag forums there has been a few have issues with the early coolers as my pic above, they run a lot more boost though over 20psi which will of course put more strain on it all, 5-10psi from the 1zz with a t25 should be fairly easy on it, its such a good package for where i want to mount but maybe the 550i is a better shout for durability.

I cant see "plenty" of other options to suit really so any more info on that welcome

[shnazzle]

I can NOT recommend any intercooler that has the crimped end tanks. Go for fully welded only.
There's plenty out there.

Its not ideal i know, have you experience of them failing ?  most of us have crimped tank coolant radiators and they last pretty well but i understand crimped tank intercoolers are not the same, i guess the varying pressures unlike pretty constant you get with coolant rads doesnt help, i would of thought as long as they mounted correctly to avoid strain on tanks from hoses etc and the pressures are kept low they should last ok.

Reading on the Jag forums there has been a few have issues with the early coolers as my pic above, they run a lot more boost though over 20psi which will of course put more strain on it all, 5-10psi from the 1zz with a t25 should be fairly easy on it, its such a good package for where i want to mount but maybe the 550i is a better shout for durability.

I cant see "plenty" of other options to suit really so any more info on that welcome

Being the proud owner of a very leaky crimped intercooler at the minute... Yes.. I do have experience  

Crimped but not plastic end tanks. I don't get the logic. Other than cost-saving. It's stupid. It's under pressure. Why would you rely on a crimped seal?

[Nvy]

I bought an ebay special and not very fond of it but will try to make it work. The coolers that you are looking for are dirt cheap on the German ebay. You can pick couple of them for 100 euros(at least the last time when I was looking for one). Also the pumps, the TurboZentrum.de is selling bosch brushless for like 85 euros but I managed to find it locally for 35(just got the part number off the site) and add to that 5 euros for the wiring connector.

All in all my setup is around 220 euros without the piping, when everything is ironed out and fitted should be close to 300 euros which is not that bad and should support 600 hp by ebay specials description. I dont believe that 600 hp number but I am not going for more than 280 because of the stock pistons. Its going to be plenty of power, far more than my talent can handle anyways.

[m1tch]

Looks like the VW Golf CUNA 2.0 TDI engine has a water to air chargecooler - might just need to chop off the intake side?

https://www.ebay.co.uk/itm/2016-Volkswagen-Golf-2-0-TDI-GTD-184-CUN-Inlet-Manifold-Charge-Cooler-04L1/193476452669?epid=28009692829&hash=item2d0c18613d:g:V-oAAOSw56pexxPc

[thetyrant]

Looks like the VW Golf CUNA 2.0 TDI engine has a water to air chargecooler - might just need to chop off the intake side?

https://www.ebay.co.uk/itm/2016-Volkswagen-Golf-2-0-TDI-GTD-184-CUN-Inlet-Manifold-Charge-Cooler-04L1/193476452669?epid=28009692829&hash=item2d0c18613d:g:V-oAAOSw56pexxPc

Might need to chop intake side off ?   i would think you definite need to!  haha

Lots of cars have the chargecooler exchanger in the intake manifold like the VW and Tailgatersaurus ones above, however im not interested in those as its a crazy amount of work to make it suitable for our cars and might as well build once from scratch if doing that, it would be nice to make one fit directly onto the intake ports of our cars like those as there is room to get a nice big core in there, but again crazy amount of work and fitting inline in boost piping is way to go

Im edging towards the beemer 550i unit just need to decide whether the left or right one will fit best, i need to get my next event out the way then i can start mocking things up in the engine bay.

[Alex Knight]

Have you thought about a Celica ST205 chargecooler?

[thetyrant]

Have you thought about a Celica ST205 chargecooler?

Yes I was really hoping to be able to use one of those, however it's just too big I think

The smaller St165 unit might work but very rare, expensive and not very efficient either, I've had a few gt4's and 205 unit it only one I would consider.

[Alex Knight]

Why do you think it's too big?

[thetyrant]

Why do you think it's too big?

Because i got someone to measure one for me and it wont fit in space i was hoping to mount it

[MannyUK]

I have moved the battery to the frunk in preparation for a charge cooler. I am willing to use a Jag or beemer one of I can find one cheaper than an eBay job.

I don't plan running more than 7-8psi as it's a stock 2zz.

I am still wondering how to plumb this in, what kind of pipes need to be run from the front.

[1979scotte]

I have moved the battery to the frunk in preparation for a charge cooler. I am willing to use a Jag or beemer one of I can find one cheaper than an eBay job.

I don't plan running more than 7-8psi as it's a stock 2zz.

I am still wondering how to plumb this in, what kind of pipes need to be run from the front.

What size turbo?
8 psi from a GT25 is a lot different to 8 psi from a gtx35

[Gaz2405]

I have moved the battery to the frunk in preparation for a charge cooler. I am willing to use a Jag or beemer one of I can find one cheaper than an eBay job.

I don't plan running more than 7-8psi as it's a stock 2zz.

I am still wondering how to plumb this in, what kind of pipes need to be run from the front.

I used 19mm ID pipes front to back for charge cooler duties.

Depends on what fittings you have on your cooler as well though. But wouldnt really want to go any smaller.

[MannyUK]

What size turbo?
8 psi from a GT25 is a lot different to 8 psi from a gtx35

GTX2860rG2

[1979scotte]

What size turbo?
8 psi from a GT25 is a lot different to 8 psi from a gtx35

GTX2860rG2

Now that's a proper turbo.

Makes a change to see a modern turbo on an MR2.

[lancs_lad]

I'm running a eBay special 5x8" barrel type with 3" inlet / outlet. Kept my AITs down within 20'F of ambient during a hard day on the dyno - cost me £55!

[MannyUK]

I'm running a eBay special 5x8" barrel type with 3" inlet / outlet. Kept my AITs down within 20'F of ambient during a hard day on the dyno - cost me £55!

Can you post a link to what you bought please?