Hi guys i need some advice to be fair if anyone can help please im fitting a 550bhp cossy turbo lump into my westfield and im having issues finding a location for the large intercooler now, all is not lost but not quite happy with its location thats all it seems wrong thats all....

My options are limited

Right i will try and explain....

With radiator and intercooler mounted as far forward as i can get it for nose cone fitting the intercooler will ethier...

1, Slot in behind the radiator and oil cooler fits nice looks right and can be piped up quite neatly and easy....

2, Intercooler can be mounted flat like on an impreza turbo again looks ok, but pipes alot worse to route to turbo etc.

Now the problem i have is all front mounted intercoolers seem to be in front of radiators not behind, my issue is i cant do that as the 76mm hose outlets wont go round or under or over the radiator so i can not fit intercooler at front of radiator... this causing the problem of warm air flowing through radiator then going through intercooler ???

Second option is doing very similar to be fair just on a different plain ie flat not verticle mount...


Whats peoples thoughts ???


Rob

Always a challenge this I had same on my turbo cars,

Link to a west field I was with on a photo shoot, he mounted it flat and made a scope for it, can just make it out in the cover pic,

Poss not the best location as normally get low airflow here? But you could also mount a electric fan to improve flow etc on the intercooler?


http://www.completekitcar.co.uk/Issue/march2010.html

Never behind the cars main radiator, it will just exchange hot air with hotter !

If you cannot get in the intercooler in front of the main rad then you must duct so that airflow is through the main radiator is kept away from the intercooler.

If you cannot achieve this with an air to air solution then look for a more complex air-water solution.

NB/ make sure the intake is also getting fresh air externally as well !

Regards Mark

Charge cooling is the answer. The charge cooled radiator can be mounted in front of the engine cooling radiator as it only needs 1" dia hoses.

Also you will get less turbo lag as the intercooler can be mounted close to the engine and the induction path is shortened.

Thats the way I am going.

Alternatively consider water injection?

you may want to consider water injection , since air temps can cause det .

air to air will always be more efficient , your only option may be charge cooling ...

Fitted mine behind the engine in a box that has a air duct from the scoop on the bonnet. The cold air goes through the intercooler and splits and exits both sides of the bonnet, works a treat.

There's a nice solution to your problems on this page

http://passionford.com/forum/restorations-rebuilds-and-projects/254591-frijj-the-white-westy-im-declaring-it-finished-55.html

although it may not be the cheapest option available.

Check out Hicost's photo archive.

He has a high power Cossie so there'll be plenty of hints there.

HTH,
James

i used a pace charge cooler off an escort turbo on mine, figured if it was good enough for an escort cosworth it would work well on my saab turbo lump. my charge temps are usually around 35-45deg max but im not running 500bhp like you plan to. look at something like pwr dont think they are as good as the pace ones but they are cheaper. p.s the bore on the pipes to the front rad is typically only 11-15mm not 1 inch like someone stated.

if you go on my photobucket i think there are some pictures in there

click for photobucket

make it fit infront,

or charge cool but that not cheap, but i suppose a 550bhp cossie engine isnt either!

my cooler at the front of mine pokes out of the sides of the body work and the boost hoses run out of the nose cone, but it a big cooler and will do the job

quote:

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p.s the bore on the pipes to the front rad is typically only 11-15mm not 1 inch like someone stated.

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For 550bhp you will need about 30psi.
Going to 30psi it will be at least 170degC when it leaves the turbo.

If you put the intercooler in-front of the radiator then it will take much more heat out of it.

550bhp will also need a decent radiator.
Check our Davids intercooler set-up.


Rad fitting 2


I have wondered whether a v-mount design might work, but you'd have to make a really nice exit path for all the air.


If you are thinking of picking up a book on this stuff then I'd recommend A. Graham Bell's book on Forced Induction to be a easy to read guide.

Good luck

Matt