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emo Charge Cooler

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26 Mar 2012 11:22 #13088

Well now I've got my new engine run in, another problem arises - the MAT temp had rocketed! used to stick at around 40 deg. even when pushed but it started getting up into the 70's and killing any power gain that I was getting from the stage 2 and HT07. I think it's a combination of the new engine and the new exhaust manifold (wish I'd lagged lt but it looked nice  ) so something needed to be done!

The options for uprated intercoolers for the AZ-1 are a bit limited. ARC made one (v pricey) or get one made. so I decided to go with one of these http://www.votionspeed.com/servlet/the-1044/Barrel-Style-Liquid-to/Detail

Here it is fitted to a home made bracket that uses the mounts for the old intercooler pipework.



My original plan was to mount a small bike rad where the old intercooler used to be but there wasn't the space or the airflow to be practical so I went for a rad (cheepo ebay oil cooler) mounted infront of the existing rads. I'm going to need to modify the under bonnet tray slightly to clear the new pipework so that hasn't gone back yet.



Pump lives on the bulkhead behind the driver's seat. The hard pipes that run from the front to the rear of the car, as well as most of the other pipe joiners, are 15mm domestic copper pipe (the pre-soldered joiners for this make a perfect bead for 16mm rubber hose)



(note to self - must sort out the surface rust before it gets any worse)

From the back you cant actually see a lot, apart from some extra pipework.



From the other side, things are definately a bit different. Air outlet pipe from the turbo is a somewhat modified cappo one (still neeeds a cleanup and polish) - while I was doing it I added a pipe so I could fit the Blitz BOV I've had lying around for ages.



So did it work???

Yes very much so, after a bit of testing I haven't got the MAT temp to go more than 5 degrees higher than the outside air temp :smile:

The downside - extra complexity and weight (about 6 kgs). Probabley not worth it on a cappo, where you can fit a larger intercooler, but on mid/rear engined cars or cars with limited space, definately worth considering.

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26 Mar 2012 12:02 #13090

Nice write up!  :thumb:

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26 Mar 2012 13:03 #13092

Nice install, so just out of curiousity, how do these actually work.

Im going for a fmic on the zato as ive ordered one up already and i think i should be able to make it fit without having to cut up the front bumper :thumb:

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26 Mar 2012 13:31 #13097

^ It's just a water to air intercooler, rather than air to air like a normal intercooler, which is why it needs a rad to feed it cold water.

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27 Mar 2012 08:39 #13110

When I went on there web site it wasn't clear if it runs on a seperate water redo our or from the engine water cooling system?

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27 Mar 2012 14:15 #13111

runs with it's own water supply, the engine cooling water would be too hot

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27 Mar 2012 15:27 #13114

Ment reservoir. GRRR to ifone predictive text lol. 

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27 Mar 2012 17:40 #13117

LoL  :lol:
Seems to cope ok without one - once the system is full the water just circulates nicely.

Pig to fill up though, the only place I could mount a filler was slightly lower than the cooler so I need to jack up the back of the car to fill it properly. Filler lives just infront of the battery - you can see it here http://forum.keikarsinthepark.co.uk/MGalleryItem.php?id=1702

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