Originally Posted by
FiestaForever
I have a question about water and alcohol injection systems, if any one has had any knowledge of, or experience with them, on forced induction air intakes. If you can help, give advice on the subject, or even are from an engineering back ground, it would be awesome.
I am making myself a front mount intercooler that has an integrated water injection system. The intercooler will most probably be connected post supercharger with the air being drawn from the original front mount snorkel on a Fiesta mk6.5 and being blown through it before entering the throttle body, and intake manifold. Would it be better to be drawing the cooled moistened air through the intercooler system instead, or would it matter as the cars intake will also be drawing in the air towards it??
The shell will be of 3mm sheet aluminium, it is light weight but rigid, I cannot weld so I have opted for marine epoxy, liquid weld. The strength and pressure resistance of the epoxy is very high in PSI. The water feed will be from a 5ltr jerry can in the boot, being pumped with a high pressure water pump up to 130 psi to feed the intercooler fluid inlet feed. I have brass compression fittings and stainless steel braided lines for optimal performance of the system. The whole system will be automated with a water level sensor to keep water levels at sufficient capacity, if the water level gets too low the electrical system shuts down automatically, and the water injection stops it is now used as a regular intercooler. The whole system may be connected to a switch in the cockpit.
Is there any specific route that would be easy to run water lines from the rear of the car to the front. Are there many grommets that can be used as such , or is there a safe place that new grommet holes can be drilled on the fiesta mk6.5?
So many questions LOL.
I have acquired the raw materials and hardware needed for the job it is now a case of RnD phase to see what works, and if any improvements can be achieved within its functionality when the prototype is ready.
Your time is appreciated, many thanks, A ford enthusiast.
mmmm WTF.
You've more than a little research to do, as you're all over the place. The advice is do some proper research.
First WTF. "The intercooler will most probably be connected post supercharger"....you cannot be serious ? The only place for a charge cooler core is after the compressor. There is no probably about it.
Second....What do you think would happen to "moist" air if it was confronted with multiple cool surfaces....it will gather on those surfaces and run off. Spraying water internally into an IC core is not the way to do things. Spray it between the IC and throttle. This is by far the easiest option even if there are other locations that can be used.
Third....while some have used epoxies for such things, I would not have high hopes of it holding together for long. Based around that, keep any end tanks small as possible, which is sort of counter productive, but will reduce the forces acting trying to blow it apart. And rather than flat sections, use naturally strong sections like a U shape, etc
And whatever you're actually gluing together, give those surfaces as much surface area as you can for the epoxy to grip.
As for whatever you're trying to do with the wiring and for whatever reason....bonkers.
Some basics, albeit with a proper controlled injection into the intake. This is far above your level or what you need to be doing though, but same principals apply.
Whilst it's novel to try and build something yourself....kits are so cheap, why even bother ? Especially when you don't really know what you're doing.
Buy a kit, install as per instructions. Job done.
Then seek a competent tuner to help optimise the use of it, whilst still remaining safe....if you actually even need it in the first place.