[eric@helix]

Here are a couple of pics of the new Helix Front Mount Intercooler prototype. It is the first of two that we are testing. This intercooler design is unique in that it has a bigger frontal ambient face combined with thicker-than-stock core that seals off to the radiator fan/shroud. The cast end tanks have factory mounting points and factory charge pipe angles. We will be testing intercoolers with varying ambient and charge fin heights so we can sell the intercooler that will provide the best results. The intercooler pictured has 3/8” ambient fin height and ¼” charge fin height with 10 charge rows. the other intercooler will have ¼” ambient fin height and ¼” charge row height with 14 charge rows. Whatever variation provides the best results in temperature drop, pressure drop and recovery is the cooler we will sell.

[retrodrive]

looking forward to testing results. looks pretty cool.

[LKNDC]

What do you think the cost will be around?

[E90Russ]

I remember you guys from the MINI tuning world. Definitely interested as you guys have a great reputation.

[AR230WAKEBOARDER]

Looks great! I had helix test pipes on my SC g35. They had great figment and were very reasonable.

[1clean335i]

interesting design. cant say that i've seen one like that before but will be looking forward to seeing the results

[dmm325]

what kind of modifications, if any, will there be to get it as the front mount?

[TurboBullett@Ambient Thermal Management]

no modifications, direct bolt on!

[Mattscott]

Looks sweet guys!

[BzzzBom]

Eric at Helix is awesome. Helix is one of the best names in the MINI tuning world. Give Eric a call. He is a super nice guy and their products are top notch.

[TurboBullett@Ambient Thermal Management]

Originally Posted by 1clean335i

interesting design. cant say that i've seen one like that before but will be looking forward to seeing the results

That's because you haven't seen one like that before When we were looking at the car's available captive area this idea jumped out at me as it was the only way to allow for more frontal area, increased core size and maintain the factory like seal in the radiator shroud/fan.

[doba_s]

Do you have any pics with it on your car ? I would like to see some numbers ...

[sambonator]

Looks very promising!

[TurboBullett@Ambient Thermal Management]

thanks for all the great comments guys, we'll get some installed pics this week and will begin testing the 1st core once that is done we will test the 2nd core and release the data of the intercooler we will release against the stock intercooler.

[Boostin335]

looks good

[Bimmer335i07]

Let me know if you need a e90 beta tester for any of your products. Seems like I take a drive to Philly pretty often these days. Just got back from the Philadelphia zoo today.

I would have stopped by and said hi, but I took the Navigator today and did not have your address in my nav.

See you guys soon!

Scott

[Cadillac Johnson]

Sorry, but that's a terrible design.

Increasing the thickness really does nothing for cooling. All this intercooler looks like it will do is increase lag and add weight.

The second half of any core (thickness) does only 1/4 of the work of cooling the charge air. Adding thickness to the core does improve efficiency, but the gains are less and less as the core gets thicker, and the downside is that it becomes harder to get the air to pass through the core. Since the same (or lesser) volume of (cooling) air passes through the core, the air first contacts and transfers heat out of the front of the intercooler, and thus is hotter by the time it reaches the back half of the intercooler's thickness, and has less (or no) capacity to absorb out additional heat from the intercooler. It also moves more slowly through the core due to the increased thickness, compared to a 3" or 3.5" thick core.

[LKNDC]

We will just have to wait and see the results.

[bnj]

Originally Posted by Cadillac Johnson

Sorry, but that's a terrible design.

Increasing the thickness really does nothing for cooling. All this intercooler looks like it will do is increase lag and add weight.

The second half of any core (thickness) does only 1/4 of the work of cooling the charge air. Adding thickness to the core does improve efficiency, but the gains are less and less as the core gets thicker, and the downside is that it becomes harder to get the air to pass through the core. Since the same (or lesser) volume of (cooling) air passes through the core, the air first contacts and transfers heat out of the front of the intercooler, and thus is hotter by the time it reaches the back half of the intercooler's thickness, and has less (or no) capacity to absorb out additional heat from the intercooler. It also moves more slowly through the core due to the increased thickness, compared to a 3" or 3.5" thick core.

How much is the frontal area and thickness increased compared to stock? I think your assumption about the changes in the dimensions are wrong.

[TurboBullett@Ambient Thermal Management]

Originally Posted by Cadillac Johnson

Sorry, but that's a terrible design.

Increasing the thickness really does nothing for cooling. All this intercooler looks like it will do is increase lag and add weight.

The second half of any core (thickness) does only 1/4 of the work of cooling the charge air. Adding thickness to the core does improve efficiency, but the gains are less and less as the core gets thicker, and the downside is that it becomes harder to get the air to pass through the core. Since the same (or lesser) volume of (cooling) air passes through the core, the air first contacts and transfers heat out of the front of the intercooler, and thus is hotter by the time it reaches the back half of the intercooler's thickness, and has less (or no) capacity to absorb out additional heat from the intercooler. It also moves more slowly through the core due to the increased thickness, compared to a 3" or 3.5" thick core.

This is not merely a thicker direct fit intercooler. we increased frontal area by 56% over stock and its ambient face is bigger than the other direct fits

so by your analogy if we increase front 1/2 thickness by 56% back half thickness should have 56% less of a heat removal job to do and become 56% more effective right? keeping the back half factory like was a design element we wanted to keep as we didn't want to lose the advantage of the factory draw through fan and shroud.

increased weight? an intercooler is a heat sink if you have a cold mass of higher weight it has more of an ability to absorb heat. keeping this mass cool can be achieved in 2 ways:
increased frontal area *check*
a draw through fan *check*

moving air through the core more slowly or quickly is one design element you play with in an intercooler design, you only have the chance to cool the charge down while its IN the core, thats why we are testing 2 different cores of varying fin geometries and releasing the best design!

[TurboBullett@Ambient Thermal Management]

Originally Posted by bnj

How much is the frontal area and thickness increased compared to stock? I think your assumption about the changes in the dimensions are wrong.

frontal area and core volume are increased by approximately 56%.

[DrH]

Originally Posted by Cadillac Johnson

Sorry, but that's a terrible design.

Increasing the thickness really does nothing for cooling. All this intercooler looks like it will do is increase lag and add weight.

The second half of any core (thickness) does only 1/4 of the work of cooling the charge air. Adding thickness to the core does improve efficiency, but the gains are less and less as the core gets thicker, and the downside is that it becomes harder to get the air to pass through the core. Since the same (or lesser) volume of (cooling) air passes through the core, the air first contacts and transfers heat out of the front of the intercooler, and thus is hotter by the time it reaches the back half of the intercooler's thickness, and has less (or no) capacity to absorb out additional heat from the intercooler. It also moves more slowly through the core due to the increased thickness, compared to a 3" or 3.5" thick core.

His logic seems sound.. Only results to the contrary will prove him wrong