Anyone else been toying with the idea of adding an air/water intercooler to your Aerocharger stage II setup? (I got inspired after seeing the RS air/water setup) I'm thinking of a small intercooler that would sit between the engine and firewall between the turbo and the intake plenum. This would eliminate all of the extra plumbing needed to use a front mount IC. I know there is additional complexity with the water plumbing, pump, reservoir and heat exchangers. It will be a challenge. I'm just curious if anyone else might be interested in it if I develop it. Since I'll probably have custom end tanks made, it might make sense to do more than one at at time. Or at least, be able to make more at a later date.
Air/Water Intercooler for A/C stage II upgrade?
Penguini66
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Anyone else been toying with the idea of adding an air/water intercooler to your Aerocharger stage II setup? (I got inspired after seeing the RS air/water setup) I'm thinking of a small intercooler that would sit between the engine and firewall between the turbo and the intake plenum. This would eliminate all of the extra plumbing needed to use a front mount IC. I know there is additional complexity with the water plumbing, pump, reservoir and heat exchangers. It will be a challenge. I'm just curious if anyone else might be interested in it if I develop it. Since I'll probably have custom end tanks made, it might make sense to do more than one at at time. Or at least, be able to make more at a later date.
I was keen on the same idea, but the space back there is really less than you think... spearco and pwr both are 2 big... I have been looking for suggestions in my air/water post, no one seems to even want to venture a guess... I have an intercooler set up from a GMC Syclone I will be fitting to my AC II if time permits and weather stays warm in WI. If I lower the AC cold air intake, re-locate the brake fluid container and the DPFE, there is room on top of the engine and under the stock hood for the Syclone a/w intercooler. Looks like the stock Syclone radiator will fit up front where the AC III intercooler goes. I'll take picts, but do not know how to post to the list, but could probably e-mail to someone who can, or has web page space.
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Yea, I agree with you. There is not that much room back there. I guess there is only one way to find out and I don't know if anyone else has actually attempted it. Looks like its you and I for now.
I also thought of mounting it on top of the engine. But, that eliminates the simplicity of the charge tubes. If I was to go top mount air/water I guess I could get rid of the aerocharger plenum and sfms fifth injector. Since you don't have the sfms, you don't need to maintain the plenum. Thanks, I almost forgot that I wont need the plenum once I go MIC.
So its: Mount the ic on top of the engine. The ic outlet will sit right over the throttle body at a 90 degree angle to the core. Then route the charge tube up over the engine to the front of the ic?
I also thought of mounting it on top of the engine. But, that eliminates the simplicity of the charge tubes. If I was to go top mount air/water I guess I could get rid of the aerocharger plenum and sfms fifth injector. Since you don't have the sfms, you don't need to maintain the plenum. Thanks, I almost forgot that I wont need the plenum once I go MIC.
So its: Mount the ic on top of the engine. The ic outlet will sit right over the throttle body at a 90 degree angle to the core. Then route the charge tube up over the engine to the front of the ic?
I'm am still planning on running an A/W setup too. I have the AC2, but it won't look like and AC2 when I'm done.
I'm planning on moving the turbo up front, under the header, then running charge air tubes up beside the engine, with an A/W box where the filter used to be, then right to the throttle body. Just like the RS. The package just makes so much sense.
I'm planning on moving the turbo up front, under the header, then running charge air tubes up beside the engine, with an A/W box where the filter used to be, then right to the throttle body. Just like the RS. The package just makes so much sense.
P66- the intercooler sits on top of the motor, to the driver side, and the charge outlet is not quite even with the throttle body. I have to make some sort of 90 degree oval to round with a slight twist adaptor. Should be fun. The outlet of the I/C is maybe 3-4" from the nearest edge of the throttle body, if that makes sence. The charge intake to the I/C is low and on the other side of the I/C, so from the existing Aerocharger tubing from the turbo up behind the engine, I will need to run a basically straight tube, (with a few slight bends of course) with a 90 degree on the end to connect with the I/C. It really doesn't look that hard.
P-51. I really like your idea of a front mount Aerocharger, but in stock form the exhaust enters up from th bottom, and now you are going to take it in 180 degrees from that, down from the top. Can you "clock" an Aerocharger like that with out upsetting the wicking system, or is there something else going on here I haven't gotten yet. If you can clock an AC, I'd like to know, so I can clock mine to get the charge outlet pointing up, as I have no reason for it to go down, not using the factory suggested I/C system.
P-51. I really like your idea of a front mount Aerocharger, but in stock form the exhaust enters up from th bottom, and now you are going to take it in 180 degrees from that, down from the top. Can you "clock" an Aerocharger like that with out upsetting the wicking system, or is there something else going on here I haven't gotten yet. If you can clock an AC, I'd like to know, so I can clock mine to get the charge outlet pointing up, as I have no reason for it to go down, not using the factory suggested I/C system.
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I am running an air to water intercooler it is a PWR barrel type and i love it
tom
tom
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Bye the way, if I can get the PWR Barrel to fit, it's getting sandblasted and painted flat black. Too much bling bling for me.
![Image]()
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I guess it will be behind the engine and out of sight so I could leave it chrome. Besides, black absorbs heat.
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Wow, that is pretty cool! I wonder how well this would work compared to my HUGE FMIC? This would most likely help the response quite a bit!
Looks like what the JRSC uses on the Mazda Miata setup!
Looks like what the JRSC uses on the Mazda Miata setup!
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I got one and love it there small compact and easy to use
keep in mind you will need a tank ,pump,lines, fittings,etc
What i did was make a tank to fit in the spair tire area
pump) I went to Northern Hydrolics and got a pump for a motor home water pump for the shower etc 35.00
hose) commercial garden hose 6.95
works great ,i have not had a chance to put mine on the dyno i will next week with a cooler air charge i should be able to add some timing
i will also hit the nitrous and see if i can hit the 400hp at the wheels mark
![Image]()
tom
keep in mind you will need a tank ,pump,lines, fittings,etc
What i did was make a tank to fit in the spair tire area
pump) I went to Northern Hydrolics and got a pump for a motor home water pump for the shower etc 35.00
hose) commercial garden hose 6.95
works great ,i have not had a chance to put mine on the dyno i will next week with a cooler air charge i should be able to add some timing
i will also hit the nitrous and see if i can hit the 400hp at the wheels mark
tom
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I just got off the phone and got approximate dimensions for the smallest PWR barrel liquid/air IC. With the end tanks, it is 4" in diameter and about 11" total length (6" core with 2.5" end tanks). With 2.5" inlet and outlet. He said that they just put one on a car that made 380hp at the wheels. I guess tonight I'll make up a cardboard mock up and see If I can get it to fit behind the engine.
Yes, I'm one of the new guys on the yahoo group. Hope I didn't make a fool of myself. They also pointed me toward the PWR barrel IC. And if Tom uses it, it must be good.
![Image]()
Anybody remember off hand what size the charge tubes are on the Aerocharger kit? I'm pretty sure that they are smaller than 2.5".
Yes, I'm one of the new guys on the yahoo group. Hope I didn't make a fool of myself. They also pointed me toward the PWR barrel IC. And if Tom uses it, it must be good.
Anybody remember off hand what size the charge tubes are on the Aerocharger kit? I'm pretty sure that they are smaller than 2.5".
Tom, you're not going to have any coolers up front at all? Just an icewater tank?
Are you still going to use the A/A intercooler, and have this thing after it with an icewater tank just for drag racing?
Interesting idea.
I found this really neat system. It basically has two cores. The air goes through the first core, that is a standard A/W intercooler, then there is a second core right behind that they are pumping AirConditioning refrigerant through to chill the air even more.
Are you still going to use the A/A intercooler, and have this thing after it with an icewater tank just for drag racing?
Interesting idea.
I found this really neat system. It basically has two cores. The air goes through the first core, that is a standard A/W intercooler, then there is a second core right behind that they are pumping AirConditioning refrigerant through to chill the air even more.
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The PWR intercooler was so easy to install all i had to do was remove the air to air , make 1 pipe and install the air to water in the same location
tom
tom
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The rain finally stopped. I went outside after work and tried my paper template of the smallest PWR intercooler. It's tight but I think I will fit!
![Image]()
I'll need at least two new charge pipes. And I'll have to find a way to go from the 1.75 charge pipes to the 2.5" inlet/outlet of the intercooler. I think I'm going to have to take it to someone to fabricate the new pipes. How difficult are the new pipes going to be to fabricate?
I envision a new pipe coming from the compressor outlet and going under the turbo just like the standard stage II first pipe. The only difference would be that this pipe would now have to travel more toward the passenger side of the engine bay. The bottom end of the ic will be just above the boot on the drive shaft. (note to self: leave enough room for full suspension travel) I'll need to keep the intercooler low enough so I dont induce any exterme bends in the top pipe. The ic will sit at an almost vertical position with a slight angle towards the drivers side and maybe a slight angle towards the front as well. The top pipe, with any luck, will look somewhat like an "S". Then it's back into the aerocharger plenum. Or, since I'm going to go MIC sometime soon, should I trash the plenum? I wish I had a complete 3D model of the Focus so I could lay it all out in Solid Works or Pro-E.
Well, there's only one way to find out.
[ 09-27-2002, 05:03 PM: Message edited by: Penguini66 ]
I envision a new pipe coming from the compressor outlet and going under the turbo just like the standard stage II first pipe. The only difference would be that this pipe would now have to travel more toward the passenger side of the engine bay. The bottom end of the ic will be just above the boot on the drive shaft. (note to self: leave enough room for full suspension travel) I'll need to keep the intercooler low enough so I dont induce any exterme bends in the top pipe. The ic will sit at an almost vertical position with a slight angle towards the drivers side and maybe a slight angle towards the front as well. The top pipe, with any luck, will look somewhat like an "S". Then it's back into the aerocharger plenum. Or, since I'm going to go MIC sometime soon, should I trash the plenum? I wish I had a complete 3D model of the Focus so I could lay it all out in Solid Works or Pro-E.
Well, there's only one way to find out.
[ 09-27-2002, 05:03 PM: Message edited by: Penguini66 ]
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