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Turbo and supercharger applications...

New SC project - Intercooler

Old 08-10-2012, 05:03 PM
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Default New SC project - Intercooler

I have been slowly getting the parts to built my own W2A intercooler for my SC. Still in the mock up stages but should have it all together and running in a couple months. This has been a project I have toyed with for quite awhile but was hesistant with so many failures by others at getting it done. I am confident I have everythng worked out and it should go pretty smoothly. Once I have run it for a bit to work out any bugs I am going to wrinkle blue powder coat everything, let me know what you think.

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Pipes are just scraps I had laying around but were actually pretty close on sizing already.

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Old 08-10-2012, 06:03 PM
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I want one cant wait to see the end results
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Old 08-10-2012, 08:43 PM
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Interested to see temp readings on the hot and cold side of the intercooler. Looks like you are doing some serious work!
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Old 08-10-2012, 10:48 PM
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please please post dyno numbers when your done. im running the same setup with a pwr intercooler
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Old 08-11-2012, 01:19 AM
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Where did you find that intercooler? I've looked for one like that, but never found one that length. Do you plan on using a reservoir? Are you running a bigger intake pipe at the maf or do you have an adapter there?
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Old 08-11-2012, 02:48 AM
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Originally Posted by syberspyder View Post
Where did you find that intercooler? I've looked for one like that, but never found one that length. Do you plan on using a reservoir? Are you running a bigger intake pipe at the maf or do you have an adapter there?
Custom intercooler to my specs to fit in the real estate on top of the engine. No I am not using a reservoir, using a high flow pump. I am changing the intake size from the 2.5 on the stock box to 3.5 inches which is what is the size on the intake of the SC. This part will require a retune because of changing that intake cross section at the maf.
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Old 08-11-2012, 01:35 PM
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Custom? Sounds expensive. I asked about a reservoir because I have the same heat exchanger and it doesn't hold that much(32oz.). I knew the inlet at the sc was bigger, I was wondering if you had a reducing insert or we're getting it tuned
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Old 08-15-2012, 10:14 PM
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I will have to compare notes with you when I finally get around to my W2A build.
Who are you buying parts from?
What is the max flow rate on your water pump?

I am going to start with this kit and get the custom parts as I need them for Form and Fit.
I moved my battery to the trunk and swapped to a Braille battery too. I want to fit the W2A exchange unit where the battery used to be.
(the battery tray is gone too)
http://www.frozenboost.com/product_i...b9413ace80985d
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Old 08-16-2012, 01:20 AM
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How's this coming along.
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Old 08-19-2012, 04:34 AM
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Had to order some more tubing to finish plumbing it, then off to finish welding then can put it together and test for a bit before powder coating. I am probably 3-4 weeks out before running it, out of town a couple weekends.
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Old 08-31-2012, 01:25 AM
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Very excited for this.
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Old 09-01-2012, 10:49 PM
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I have a week off now and plan to get everything mounted and plumbed in. I have got the pipes mock up completed and will have my Dad weld them up this week. Need still make a custom mount for the pump. One spot I wasn't expecting to do some fab work was on the passenger side, going to have to make a bracket to reposition the AC line that was already relocated from the TRD kit.

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Old 09-02-2012, 01:39 AM
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That looks good. How you holding up the intercooler or just sitting on the valve cover.
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Old 09-02-2012, 01:57 AM
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Originally Posted by JDMTC5 View Post
That looks good. How you holding up the intercooler or just sitting on the valve cover.
There are going to be two rubber spacers to lift it off the coils and I will be adding one tab on the passenger side to attach to one of the valve cover bolts.
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Old 09-02-2012, 08:57 PM
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Looks good, any plans to measure inlet/outlet temps? I'm guessing the part in the water line is for filling the liquid? Where did you get that, I've read its important to fill and cap at the high point to remove air bubbles, which looks like you got that covered.
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Old 09-04-2012, 08:26 PM
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Interesting setup.

Probably look really good when its done.

Watchin...
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Old 09-05-2012, 02:11 PM
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Originally Posted by AZGuy View Post
There are going to be two rubber spacers to lift it off the coils and I will be adding one tab on the passenger side to attach to one of the valve cover bolts.
Im a little worried that if u wanted to swap out spark plugs or do a inspection would u have have to re-Dyno or re-test the system? New to the turbo/charger systems.

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Old 09-05-2012, 05:11 PM
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Originally Posted by HOLLOWMANGT69 View Post
Im a little worried that if u wanted to swap out spark plugs or do a inspection would u have have to re-Dyno or re-test the system? New to the turbo/charger systems.

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Simple answer is no, if you had to do that it wouldn't be any different than say when I took the entire SC off to rebuild.
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Old 09-05-2012, 05:12 PM
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Originally Posted by syberspyder View Post
Looks good, any plans to measure inlet/outlet temps? I'm guessing the part in the water line is for filling the liquid? Where did you get that, I've read its important to fill and cap at the high point to remove air bubbles, which looks like you got that covered.
The filler is from frozen boost, just removed the hose barbs and hard lined it.
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Old 09-05-2012, 05:15 PM
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Update, got everything plumbed it and made the bracket to hold the pump, basiclly the same style that ptuning did for the water injection. I just need to wire in the pump and make a little bracket for the AC line then I am just waiting on the intake piping to get wleded up.

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