Intercooler Test,Non Scientific

[Juno]

Now there is no science to this other than my hand is made of Skin

The car has just had a good one hour cross country dash, after getting on the drive,parking,opening the clam all without rushing allowing some heat soak to take place everything is only tepid to the touch!

Take a close look at our 2nd internal diffuser which is directly and only inches from the exhaust, the air flow through the gap must be taking heat away. I have attempted to touch others and given in at the risk of getting 3rd degree burns.

I will wait for the comments with baited breath !!!


http://www.youtube.com/watch?v=vD4LHtADG7o&fea...

[daddysumo]

Well done Baz... the hot side of your intercooler and the hot boost pipe straight from the front turbo are not hot after 1 hour of spirited driving....that's unbelievably good !!

[Juno]

daddysumo said:

Well done Baz... the hot side of your intercooler and the hot boost pipe straight from the front turbo are not hot after 1 hour of spirited driving....that's unbelievably good !!

Thanks, one day i will remember to bring the temp gun back from the workshop then I can take a scientific look at the difference between the Turbo pipe temps and intercooler temps. Obviously there is a difference.

Before I changed the set up the intercooler housing box would burn you if touched.

[Adrian W]

Next time you do this test, can you grab hold of the exhaust and let use know if it is hot,

[Juno]

Adrian W said:

Next time you do this test, can you grab hold of the exhaust and let use know if it is hot,

No Ta

But im quite happy for you to come over and sit on it, Good to see nothing in Noble land has changed!

[Juno]

daddysumo said:

Well done Baz... the hot side of your intercooler and the hot boost pipe straight from the front turbo are not hot after 1 hour of spirited driving....that's unbelievably good !!

I mean Thank!s asuming your taking the P155, wouldnt want any missunderstanding

[Chapppers]

Imagine how cold it'd run if you'd had smooth bends instead of harsh angles in your hard pipes. Pretty good though, I guess the standard design has a lot to answer for.

[Juno]

Chapppers said:

Imagine how cold it'd run if you'd had smooth bends instead of harsh angles in your hard pipes. Pretty good though, I guess the standard design has a lot to answer for.

Ive seen the pipes when they were off and there pretty smooth on the inside,the welds do make it look a lot different on the outside but obviously its the inside that counts. We also got rid of some bends.

Edited by Juno on Tuesday 26th June 00:03

[wessexrfc]

Adrian W said:

Next time you do this test, can you grab hold of the exhaust and let use know if it is hot,

????????

[Juno]

wessexrfc said:

????????

What sort of reply do you expect from the forum ?

Just had the 044 fitted and brought the car the long way home via an hour of twisty quiet roads. Bloody noisy that new pump!

[daddysumo]

Juno said:

daddysumo said:

Well done Baz... the hot side of your intercooler and the hot boost pipe straight from the front turbo are not hot after 1 hour of spirited driving....that's unbelievably good !!

I mean Thank!s asuming your taking the P155, wouldnt want any missunderstanding

Why would you think that ? I can put my hand on my Turbo exhaust housing under the same circumstances and it feels only warm to the touch... I was actually impressed that your intercooler is so free flowing and efficient that the gasses that exit your turbo, (that are in excess of 100 deg C), are transfered through to the engine without any heat transfer to the alumiminm thermally conductive pipework pre I/C, but then do conduct heat through the aluminium I/C just inches further along... as I said very impressed if what you have stated is true...

BTW I can touch my turbo because it is blanketed....

[Chapppers]

Juno said:

Chapppers said:

Imagine how cold it'd run if you'd had smooth bends instead of harsh angles in your hard pipes. Pretty good though, I guess the standard design has a lot to answer for.

Ive seen the pipes when they were off and there pretty smooth on the inside,the welds do make it look a lot different on the outside but obviously its the inside that counts. We also got rid of some bends.

Unfortunately it's the inherent shape rather than smoothness, you've gone for a step change in direction which causes a horrid vortex to form just after the inside edge. It's difficult to explain in text so I'll try to drag out some pictures. A while back a colleague of mine did some simulations and some physical tests and showed something like a 50% drop in flow if angled pipe was used rather than a decent bend.

However... If you feel like you've got decent results already then I wouldn't let it worry you, but it might be something to consider for the future. It's also more complicated and quite a bit more expensive!

[Juno]

Chapppers said:

Unfortunately it's the inherent shape rather than smoothness, you've gone for a step change in direction which causes a horrid vortex to form just after the inside edge. It's difficult to explain in text so I'll try to drag out some pictures. A while back a colleague of mine did some simulations and some physical tests and showed something like a 50% drop in flow if angled pipe was used rather than a decent bend.

However... If you feel like you've got decent results already then I wouldn't let it worry you, but it might be something to consider for the future. It's also more complicated and quite a bit more expensive!

We could always make some new pipes if there are good gains to be made. Bending would be more difficult but guess it can be done! I'll show the drawings to the workshop once you have posted them!

[Juno]

daddysumo said:

Why would you think that ? I can put my hand on my Turbo exhaust housing under the same circumstances and it feels only warm to the touch... I was actually impressed that your intercooler is so free flowing and efficient that the gasses that exit your turbo, (that are in excess of 100 deg C), are transfered through to the engine without any heat transfer to the alumiminm thermally conductive pipework pre I/C, but then do conduct heat through the aluminium I/C just inches further along... as I said very impressed if what you have stated is true...

BTW I can touch my turbo because it is blanketed....

Thank God for Turbo blankets !

[Rob_W]

Chapppers said:

Unfortunately it's the inherent shape rather than smoothness, you've gone for a step change in direction which causes a horrid vortex to form just after the inside edge. It's difficult to explain in text so I'll try to drag out some pictures. A while back a colleague of mine did some simulations and some physical tests and showed something like a 50% drop in flow if angled pipe was used rather than a decent bend.

Hi Chappers, would be very interested to see any information you have as I was considering a few mods myself.

Thanks

Rob

[alex s]

Chapppers said:

Unfortunately it's the inherent shape rather than smoothness, you've gone for a step change in direction which causes a horrid vortex to form just after the inside edge. It's difficult to explain in text so I'll try to drag out some pictures. A while back a colleague of mine did some simulations and some physical tests and showed something like a 50% drop in flow if angled pipe was used rather than a decent bend.

However... If you feel like you've got decent results already then I wouldn't let it worry you, but it might be something to consider for the future. It's also more complicated and quite a bit more expensive!

Now call me thick (which I am) but surely a couple of gently angled hoses that Juno has are still going to be better for flow than the end tank with a sharp90 degree intake on the pro alloy intercooler...or am I missing something.
Because if this is the case then barry's intercooler would flow better than the pro alloy... ( yes I know I agree with barry about something )
Flame suit on...

[Gadgeroonie]

alex s said:

Now call me thick (which I am) but surely a couple of gently angled hoses that Juno has are still going to be better for flow than the end tank with a sharp90 degree intake on the pro alloy intercooler...or am I missing something.
Because if this is the case then barry's intercooler would flow better than the pro alloy... ( yes I know I agree with barry about something )
Flame suit on...

i never understood the 90 degree bend on the proalloy intercooler - it just seems wrong

[Chapppers]

Sure, but he's still losing a lot of flow with the angles. My colleague returns tomorrow, I'll see if he'll share his simulation results. He also simulated the use of a radiator cowl vs having fans on the surface and showed large performance gains from that too.

I can't find much on google to demonstrate the problem at the moment unfortunately but it's all to do with how the air is fed gently into the direction you want rather than causing stagnation at the angle points.

I'm talking about his hard pipes rather than the intercooler, just thinking of a further improvement.

[GTO600]

[quote=Chapppers]Sure, but he's still losing a lot of flow with the angles. My colleague returns tomorrow, I'll see if he'll share his simulation results. He also simulated the use of a radiator cowl vs having fans on the surface and showed large performance gains from that too.

Threw my radiator cowling away years ago.

[Adrian W]

Does it really matter? I would have thought that in a pressurised system the largest factor that would affect performance is the compromise between volume and flow, to avoid pressure drop but to keep the volume of the pipework, end tanks and intercooler core as large as possible to maximise the heat transfer