i have three 2wd cosworth intercoolers, im planning on making one big intercooler with the cores (same idea as the one from NMS) to use with my t34 zetec turbo at up to 2bar.

which of these below would be the best way to go about it for efficiency etc? will they all cool and flow the air at the same rate etc? ignore the inlet and outlet positions.



A - standard run of the mill intercooler style

B - having the 3 intercoolers in series

C - using half of the middle 2wd intercooler on the inlet side, half on the outlet

D - cut the cores in half and weld them up to allow air flow bottom to top

any views or input welcome

 

B & C will give you a higher pressure drop for the same surface area, so not as good as A. however, the end tank design in A is crucial to get even flow through the entire core, whereas it's not as important in C and less so in B

 

B & C are shite, A could do with having the inlet and outlet on the sides and at angles.

 

I also think that RS500 style coolers are a shite design too but thats a different topic

 

 

i would of thought b and c would have cooler act's but alot more pressure drop.

 

anymore opinions people?

 

B might work better if the cores were shorter,correct me if im wrong

 

A looks the better cooler

I know jack shit on pressure drops tho...

Anyone care to explain


PS: Good pics ben

 

depends what ya want, b looks to have the most efficient cooling BUT are act's that bad ya need it ??

a looks to have the best flow but end caps need to be looked at tbh

c dont even make sence with the end caps unless ya gonna cap the middle of the center coooler

heres a silly idea btw, why not chop all 3 coolers in half and mount em like pro alloy( bottom to top) just a idea, that way ya really only need 2 and will ease fitting aswell as reduce install probs and water temps

 

b19bal, for intercooler C the centre of the middle intercooler core was going to have the end caps on the right hand side welded to it, so half would be used to flow one way (right to left) and the other half flow the other way (left to right)

good idea about cutting the cores and mounting them this way tho

 

not sure what i need yet, as im still building the car, see my sig havent even started the engine build yet either

 

A or D would be worth doing. UK seem to favour style A for IC's whereas in the US they go for IC's more like setup D.

B would pose a massive restriction, and I wouldnt even consider it.

C would be OK, but unless you actually needed both inlet and outlet on same side, I wouldnt bother with it.

 

d is same as rs 500, just on its side

 

A is more like an RS500.

but then A is like D, just turned over with shorter tubes.

 

d is like a pro alloy coooler but ya can make it shorter than a rs500 as its thicker as hes using a 3 2wd coolers thus allowing air to the rad but at the same time allows it to remain single pass to reduce presure drop

glad ya like me idea

 

cheers for the input lads, always nice having other peoples views and opinions on things

 

 

i have allready done this using the 3 intercoolers and the rolling road shows it worked well as diagram A
would deffo recomend doing it alot better than the pace one i had before.

 

cheers

 

rolling road is not a true test though, unless you have full car airflow at speed.

any improvement of an intercooler on a rolling road with limited airflow will exaggerate the results.