Intercooler Placement?

[Jon_Bmw]

Right then i need an intercooler as the hot whether and compressed air is sapping power and helping it detonate i think.

The problem is where to put one, i don't want to be grinding away half the front slam panel or the like.These are the locations i've thought about any more shout them at me. By the way i have an oil cooler.

1)Behind the kidney Grills This seems like a good place to put it as it would have good air flow to it and a bit of protection from the grills, i'e no large stones taking out half a 'cooler. The problems with it i think are- how much air flow will it stop from reaching the radiator as i don't want it overheating. The second problem how to get the hoses to the intercooler, i would guess just chop the plastic radiator funneling, but will that also reduce flow to the rad.

2)Adjacent to the radiator This would be mounted behind the passenger headlight, space is a problem with anything other than a small intercooler hitting things like the power steering pump and abs pump(possibly) Also air flow is't that great as the radiator funneling directs air away from that area.

3)Underneath the oil cooler This would be mounted underneath the oil cooler on the lower front panel(metal bit). It would have to be something like an 820 or cosworth intercooler as they are not very deep. This would have very good air flow. Problems with this are it will be very close to the ground and stones/bumps will proabably kill it very quickly.


So what are your thoughts and any other ideas, i know Ant, Mark and Alex must have some alternatives too, so any suggestions from you guys would be good too. Aswell as location what types of Intercooler, cosworth saabs, rovers.

Cheers in advance

Jon

[Ant]

Behind Kidneys is hard work, the problem is getting the charge pies in and out, I have used a Volvo 960 Turbo IC, its about the same size as the rad, has 2 2.5" inlets on the lower edges, seems to work OK

Cossie intercooler is good but too fat, I have a spare if you need one BTW

Alex has ussed 2 cossie units but ducted the air to them rather than have them straight in the airfolw, this is no real prob as long as the duct is 1/3rd the size of the IC core

Marks has a custom unit mounted in front of the rad in the area where the oil cooler should sit, the oil cooler is now behind the IC, his charge pies go in the bottom and exit below the ns main beam and pass through the panel there.

Will source some pix

Alternative units are merc sprinter/C270 cdi intercoolers, they do fit but are Ԛ£Ã”šÃ‚£ or the 330D unit which is almost identical

[Turbo-Brown]

I'd have thought a cossie in front of the oil cooler would do the job.

Definately wouldn't want to mount anything below the oil cooler though. Mine are where it used to be and are still a bit close to the ground for my liking.

There's a convenient bit of plastic beside the rad cowling which could prove useful for routing pipes through

[Jon_Bmw]

Thanks Ant that was pretty quick reply. I was having a look at the kidney grill yesterday and i agree getting the charge pipes in and out would be a bit od a headache. Just had a look at Alex's design it looks like he has had to chop the front valance right out to get them in, not really something i want to do to be honest.

Where was yours mounted ant i don't think you said, or is it mounted in the same place as marks? Those volvo 960 units are quite good, good inlet and exit port size. The next door neighbour has one, i wonder if he'll notice if it disapears probably not knowing him

What are the dimensions on your cossie intercooler, not in a rush ant, whenever bud.

[Jon_Bmw]

I'd have thought a cossie in front of the oil cooler would do the job.

Definately wouldn't want to mount anything below the oil cooler though. Mine are where it used to be and are still a bit close to the ground for my liking.

There's a convenient bit of plastic beside the rad cowling which could prove useful for routing pipes through

Alex thanks for replying too, so do you think just move the oil cooler back then mount it infont, a bit like Marks design.

That bit of plastic beside the rad cowling is for the old air box i think. Does look about the right size though.

[Ant]

Jon you are more than welcome to the Cossie IC dude, it can be persuaded to fit without too much chopping but will nedd to poke out of the front panel a tad.

I have uploaded some more pix, the yellow box in the second one shows the total size of the IC, I have yet to chop the lower front panel as I need to get the car painted @ same time and Ԛ£Ã”šÃ‚£ is short

Pix:

http://img320.imageshack.us/img320/7657 ... 0141eh.jpg

http://img320.imageshack.us/img320/17/t ... dit7ie.jpg

as you can see the oil cooler can be retained but needs a tweak to get her in, not ideal for flow but you get the idea. I kept the rad ducting and cut that to clear the IC core, no running hot issues yet, gets to 3/4 when stuck in traffic but dont they all

Electric fan req next, will fit that beweent he rad and IC and retain the viscous too for now.

the volvo IC is a good choice, got mine off ebay for Ԛ£10 !!! bargain and she is mint, may get a reploca bar and plate unit made up in alloy, one day eventually ....... I tried fitting it so the charge in/out were @ the top, aint gonna happen hence the fitmant I used, I had to midify the lower inner front crossmember with a large hammer to get the unit mounted high enough, you'll need to make brackets up though as the IC has no integral mounts, mines cupped top and bottom with a back box retaining band cut and shut to fit

Our US turbo cousins have used 2.6 widebody starion ICs to good effect BTW, some end tank mods may be required though

if you're not planning masses of boost a 1.8T golf IC can be mounted in the front o/s brake duct area and is quite effective I'm told