Another Plug-and-Play Intercooler Option

BB_cuda · 02-02-2016, 07:26 PM

If the back side of bar came to a point, the overall profile would be like a wing. That's cool. Somebody is thinking with physics and aerodynamics!

TDIwyse · 02-02-2016, 10:07 PM

Quote:

Originally Posted by iaknown

Well, I got my hands on one much sooner than expected (turns out the manufacturer is 30 minutes from me). This intercooler is muy impressivo, now I just need to test fitment ...

Well that's pretty. Are you planning on taking some data including IAT's with the VRSF and then this one? That would be interesting. Also, is this something that would work with the coupling mechanism you're using for the VRSF? Or would a new fitting solution be required?

iaknown · 02-02-2016, 10:23 PM

Quote:

Originally Posted by TDIwyse

Well that's pretty. Are you planning on taking some data including IAT's with the VRSF and then this one? That would be interesting. Also, is this something that would work with the coupling mechanism you're using for the VRSF? Or would a new fitting solution be required?

I would love to do some back to back comparisons but time may be a limiting factor. At this point I really need to see if it fits first. From some tests I've seen of these cores in other models it's safe to say it will be a considerable difference....but of course more ching.

Good question about the coupling. This intercooler actually has smaller inlets and outlets (2-1/2") than the VRSF so I need to experiment, but I don't foresee it being a problem. I have a pile of connection parts on the way

Also, I have an idea for a hard pipe on the hot side for those that prefer that.

Khedge · 02-03-2016, 12:59 AM

Sounds good... I will wait to see how everything turns out.

iaknown · 02-11-2016, 11:55 PM

Finally got some time (and motivation) to play in the shop today

Things went well....

-Got the new stepped core intercooler fitted, this intercooler is a work of art and fits very well, minimal trimming was needed.

-I am experimenting with a custom-sized beaded sleeve I made that does not require welding (or anything permanent for that matter). Fits perfectly and looks promising. This does away with the sucky factory connection altogether. No more leaking at all on this side!

-Also made a hardpipe for the turbo to intercooler connection. This will be great for the hybrid guys, minimal hose is exposed. I plan to use at least one high-heat hump connector to allow some movement.

Didn't have time to wrap the project up but all of the research and time to fabricate is paying off. Looks like we'll have a variety of options very soon for the intercooler department

petey_highboost · 02-12-2016, 03:51 AM

Looks good, now just a hard pipe is needed on the other side to replace the silicone 90*, that's the only one im worried about bursting apart.

TDIwyse · 02-12-2016, 07:40 AM

Quote:

Originally Posted by iaknown

...
This does away with the sucky factory connection altogether.
...

Hurrah for THIS.

Looking good iaknown.

iaknown · 02-12-2016, 05:50 PM

Quote:

Originally Posted by petey_highboost

Looks good, now just a hard pipe is needed on the other side to replace the silicone 90*, that's the only one im worried about bursting apart.

With the silicone elbow I'm using that has a 55+psi burst and 350 degree temp rating, I'm not worried especially since this is after the intercooler where much cooler temps will be present....

But if that's your preference I can accomodate

NC335d · 02-12-2016, 06:06 PM

Quote:

Originally Posted by iaknown

Quote:

Originally Posted by petey_highboost

Looks good, now just a hard pipe is needed on the other side to replace the silicone 90*, that's the only one im worried about bursting apart.

With the silicone elbow I'm using that has a 55+psi burst and 350 degree temp rating, I'm not worried especially since this is after the intercooler where much cooler temps will be present....

But if that's your preference I can accomodate

You'll notice a BIG difference, I def. did.

iaknown · 02-12-2016, 06:50 PM

Quote:

Originally Posted by NC335d

You'll notice a BIG difference, I def. did.

You had everything done at once right? Piping and intercooler?

NC335d · 02-12-2016, 09:09 PM

Quote:

Originally Posted by iaknown

You had everything done at once right? Piping and intercooler?

Yes.

335dlci · 02-13-2016, 12:23 AM

Are you going to dyno soon with the intercooler upgrade?

petey_highboost · 02-13-2016, 02:24 AM

Quote:

Originally Posted by 335dlci

Are you going to dyno soon with the intercooler upgrade?

I'll be doing an after intercooler dyno once installed

iaknown · 02-18-2016, 12:43 AM

All buttoned up

Did the turbo connection with a hump coupler to allow some movement...has a 500 deg. temp and a 250psi burst rating. This combination should be pretty bullet-proof.

TDIwyse · 02-18-2016, 08:04 AM

Looks good iaknown.

CO335D · 02-18-2016, 12:10 PM

Very nice Iaknown. Let me know when you get a price together for the kit. I am interested.

Bob@BPC · 02-18-2016, 10:09 PM

Looking good

do you know how much boost you are running?

iaknown · 02-18-2016, 11:47 PM

Quote:

Originally Posted by Bob@BPC

Looking good

do you know how much boost you are running?

Thanks guys!

To answer your question, not enough

I'd have to dig up my INPA logs for the dde figures but my piggyback (which actually seems less filtered/more accurate) shows right around 32 psi. Any particular reason you ask?

petey_highboost · 02-19-2016, 01:23 AM

Looks like a little longer 45* silicone coupler would work in place of the hard pipe too, no ?

Bob@BPC · 02-19-2016, 10:14 AM

Quote:

Originally Posted by iaknown

Thanks guys!

To answer your question, not enough

I'd have to dig up my INPA logs for the dde figures but my piggyback (which actually seems less filtered/more accurate) shows right around 32 psi. Any particular reason you ask?

wanted to see if the boost would drop after the install

iaknown · 02-19-2016, 06:16 PM

Quote:

Originally Posted by petey_highboost

Looks like a little longer 45* silicone coupler would work in place of the hard pipe too, no ?

That's what I had in place on the VRSF, a 3" silicone elbow. It worked well with my current boost level. That combination is being tested on a hybrid car soon so we'll see how it holds up under the higher pressures. But this setup is much more stout to be honest.

Quote:

Originally Posted by Bob@BPC

wanted to see if the boost would drop after the install

Oh....sorry, misunderstood you. Thought you meant in general. I haven't logged the boost after installing this intercooler but I will as soon as I can and report back.

iaknown · 03-16-2016, 07:54 PM

After some feedback from Petey (thanks!) I decided to go full bore....Whipped these up today on the Haas. Here is a CNC'd turbo flange that solves our leaky turbo connection. It also solves the somewhat challenging install procedure of the last sleeve I made up. I machined these to the same OD of the turbo outlet. Loctite retaining compound, a little heat (if needed) and done....a complete hot side solution that will work with the intercooler kit

02-02-2016, 07:26 PM	#45
BB_cuda Brigadier General 776 Rep 3,559 Posts Drives: 2011 335D Msport, 2013 X5D Join Date: Nov 2011 Location: Clear Lake, Texas iTrader: (0)	If the back side of bar came to a point, the overall profile would be like a wing. That's cool. Somebody is thinking with physics and aerodynamics!
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02-03-2016, 12:59 AM	#48
Khedge Enlisted Member 8 Rep 46 Posts Drives: 2011 BMW 335d Join Date: Dec 2015 Location: Texas iTrader: (0)	Sounds good... I will wait to see how everything turns out.
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02-11-2016, 11:55 PM	#49
iaknown Banned 427 Rep 1,036 Posts Drives: 335D Join Date: May 2013 Location: NJ iTrader: (1)	Finally got some time (and motivation) to play in the shop today Things went well.... -Got the new stepped core intercooler fitted, this intercooler is a work of art and fits very well, minimal trimming was needed. -I am experimenting with a custom-sized beaded sleeve I made that does not require welding (or anything permanent for that matter). Fits perfectly and looks promising. This does away with the sucky factory connection altogether. No more leaking at all on this side! -Also made a hardpipe for the turbo to intercooler connection. This will be great for the hybrid guys, minimal hose is exposed. I plan to use at least one high-heat hump connector to allow some movement. Didn't have time to wrap the project up but all of the research and time to fabricate is paying off. Looks like we'll have a variety of options very soon for the intercooler department Attached Images Last edited by iaknown; 07-18-2016 at 11:20 PM..
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02-12-2016, 03:51 AM	#50
petey_highboost Second Lieutenant 80 Rep 244 Posts Drives: '10 335D Join Date: Nov 2015 Location: albany, ny iTrader: (0)	Looks good, now just a hard pipe is needed on the other side to replace the silicone 90*, that's the only one im worried about bursting apart.
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02-13-2016, 12:23 AM	#56
335dlci Lieutenant Colonel 286 Rep 1,595 Posts Drives: 335d Join Date: Apr 2014 Location: Socal iTrader: (0)	Are you going to dyno soon with the intercooler upgrade?
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02-18-2016, 12:43 AM	#58
iaknown Banned 427 Rep 1,036 Posts Drives: 335D Join Date: May 2013 Location: NJ iTrader: (1)	All buttoned up Did the turbo connection with a hump coupler to allow some movement...has a 500 deg. temp and a 250psi burst rating. This combination should be pretty bullet-proof. Attached Images
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02-18-2016, 08:04 AM	#59
TDIwyse Colonel 617 Rep 2,408 Posts Drives: 2011 335d Join Date: Aug 2012 Location: MidWest iTrader: (0)	Looks good iaknown. __________________ 2011 335d 11.68 @ 125.71 mph 1/4 mile NHRA certified track Ram Cummins with lots-o-mods
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02-18-2016, 12:10 PM	#60
CO335D Second Lieutenant 26 Rep 218 Posts Drives: '11 335D Join Date: Oct 2014 Location: CO iTrader: (0)	Very nice Iaknown. Let me know when you get a price together for the kit. I am interested.
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02-18-2016, 10:09 PM	#61
Bob@BPC 870 Rep 642 Posts Drives: F30 328i Sport Line Join Date: Dec 2015 Location: Raleigh iTrader: (0)	Looking good do you know how much boost you are running?
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02-19-2016, 01:23 AM	#63
petey_highboost Second Lieutenant 80 Rep 244 Posts Drives: '10 335D Join Date: Nov 2015 Location: albany, ny iTrader: (0)	Looks like a little longer 45* silicone coupler would work in place of the hard pipe too, no ?
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03-16-2016, 07:54 PM	#66
iaknown Banned 427 Rep 1,036 Posts Drives: 335D Join Date: May 2013 Location: NJ iTrader: (1)	After some feedback from Petey (thanks!) I decided to go full bore....Whipped these up today on the Haas. Here is a CNC'd turbo flange that solves our leaky turbo connection. It also solves the somewhat challenging install procedure of the last sleeve I made up. I machined these to the same OD of the turbo outlet. Loctite retaining compound, a little heat (if needed) and done....a complete hot side solution that will work with the intercooler kit Attached Images
	Appreciate 2 Quote