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Old 02-15-2011, 12:14 AM   #1
AWSnare
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Default Splitter creation thread. Help me decide what design to produce!

Not many of you know me, but I am slightly better known on the GC world because of my former cars. I am about 9 months into the turbo GD world and loving every second of it! My background includes an associateís degree in plastics and polymer engineering (currently finishing for my bachelor's). I love the idea of plastics taking over the world, and I want to start making more lightweight, functional parts for my car!

I came across a problem when I swapped a vf39 into my 06 wrx tr... The hood splitter is too damn small for my intercooler! Anyways... I was looking at new options for hood splitters since I am now not running one. I looked at all of the options for hood splitters that I had, but not one of them are affordable or even worth it! Yes... they all function perfectly, but do they cool your turbo too? NOPE! (the "vents" in the side just throw air randomly around near the turbo).

I developed a splitter that gets air to the front and back of the intercooler (like the others) AND I included a way to cool the turbo as well! I can make them for less than the other guys have them too! I thought about just scrapping the whole Idea I had because I figured that no one really cares about the splitter anyways... But I want to make them out of carbon fiber and regular abs plastic (for options). I also want to develop other parts too!

Since I am too far gone into this project, I want to know what you guys think about my Idea! If there is enough interest, I will start making the mold and thermoforming them! If not, Iíll just make one for me and a few friends and call it a day.

Input please!

Thanks,
Andrew

Chimney idea (would be an add on)


Simple design (could still utilize the chimney) and be slightly cheaper to make


The most simple design (could sell even cheaper)


This one has the biggest possible opening I was able to make.


Here is my (basically final) design: Itís a 3 piece design Main splitter, rib insert for front intercooler air, and bottom seal that will have flexible rubber (much like the oem sti one).
Together view:

Exploded View:
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Last edited by AWSnare; 02-21-2011 at 10:32 AM.
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Old 02-15-2011, 12:33 AM   #2
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Pics of what you came up with would be sweet. Not sure if it would work for my 2011 or not but if so i may be interested.
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Old 02-15-2011, 01:49 AM   #3
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As requested. I have a cardboard prototype that fits perfectly (just like the design pictured). It is a 3 piece part; the center rib and the turbo air scoop are going to be made with a separate mold and will then be attached after fabricated.

The 06-07 market is what I know they will 100% fit right now. In order to make sure the other years like 02-05 would fit, I would need a tester (but I have friends with those years). 08-12 I believe would have to be a completely different design.

Last edited by AWSnare; 02-15-2011 at 02:35 AM.
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Old 02-15-2011, 06:19 AM   #4
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Which aftermarket TMIC did you design this around because they are all a bit different.
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Old 02-15-2011, 07:01 AM   #5
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Cooling a turbo is NOT needed. The OEM units give little more than a nod to this premise, I suspect mainly as a "vent" for periods of idling. In any event what you are thinking about has been done before through a chimney design and worked, but you have to account for 90,000 different TMICs and fitment issues a go-go. I have had my turbo wrapped since day zero and have had zero turbo issues. As well, I think thermodynamically speaking, keeping heat IN the turbo is better all around due to reduced heat soak and the noble gas law.

So if you think this idea is fun and easy, knock yourself out. You are not blazing a new trail though and you are in for a lot of work as in order for a splitter to be effective, it must SEAL to the intercooler. No seal = ghetto-tastic.
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Old 02-15-2011, 08:59 AM   #6
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^^^ I do agree on the turbo cooling not being necessary, but I would like to know what TMIC this was designed around. I have a Spearco and the stock STi splitter is a no go. Process West offered a splitter with their TMIC but the price is ridiculous. Perhaps I should just fab my own.
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Old 02-15-2011, 10:49 AM   #7
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Quote:
Originally Posted by Unabomber View Post
Cooling a turbo is NOT needed. The OEM units give little more than a nod to this premise, I suspect mainly as a "vent" for periods of idling. In any event what you are thinking about has been done before through a chimney design and worked, but you have to account for 90,000 different TMICs and fitment issues a go-go. I have had my turbo wrapped since day zero and have had zero turbo issues. As well, I think thermodynamically speaking, keeping heat IN the turbo is better all around due to reduced heat soak and the noble gas law.

So if you think this idea is fun and easy, knock yourself out. You are not blazing a new trail though and you are in for a lot of work as in order for a splitter to be effective, it must SEAL to the intercooler. No seal = ghetto-tastic.
Thank you! I knew I could count on you to get the info I was looking for. To at least squash the seal issue, I am going to make different seals for different intercoolers starting with the sti intercooler. Then, I have a friend with a spearco and hell, I might even buy an ebay tmic. As far as having a "perfect" application for all tmics, that wont happen for a while.

NOW the vent. Funny you mention the chimney at idle... I had a friend tell me that this is how I should interprate the vent for the turbo and I didnt buy it! If you are saying that it is tested and it works, I will make a chimney vent work with a spearco tmic since it is the largest one on the market (correct me if im wrong). This is why I also am making the splitter in pieces. The chimney could be added on if desired and if applicable.

Quote:
Originally Posted by A-man07 View Post
^^^ I do agree on the turbo cooling not being necessary, but I would like to know what TMIC this was designed around. I have a Spearco and the stock STi splitter is a no go. Process West offered a splitter with their TMIC but the price is ridiculous. Perhaps I should just fab my own.
^I have an sti one... will have a spearco for test fit as well.
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Old 02-15-2011, 11:27 AM   #8
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ABS plastic? Doesn't that have a melting temperature around 200 F? You know the hot side of the turbo gets over 1000 F right? I could see it making mince meat of this splitter (at least the "turbo vent" part of it) as soon as you hit a stop light and the air flow through the plastic stops.
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Old 02-15-2011, 11:30 AM   #9
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Quote:
Originally Posted by the suicidal eggroll
ABS plastic? Doesn't that have a melting temperature around 200 F? You know the hot side of the turbo gets close to 1500 F right? I could see it making mince meat of this splitter (at least the "turbo vent" part of it) as soon as you hit a stop light and the air flow through the plastic stops.
I'm in plastics, I know this, it's not the abs you are thinking of (slightly modified)

Obviously I will be testing this in a dd setting and a track setting before anyone outside friends gets this.
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Old 02-15-2011, 11:33 AM   #10
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Make sure you endeavor to make the seal "accordian-like" as every TMIC fits slightly off in width, length, and height.

Spearco is the biggest in CFM, but not sure if it is size wise.

If I were doing it, I would just make the chimney part some holes like the OEM one as that can throw your fitment off and I'd rather invest fitment hours on the part that REALLY counts, the intercooler area part.
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Old 02-15-2011, 11:43 AM   #11
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Quote:
Originally Posted by Unabomber
Make sure you endeavor to make the seal "accordian-like" as every TMIC fits slightly off in width, length, and height.

Spearco is the biggest in CFM, but not sure if it is size wise.

If I were doing it, I would just make the chimney part some holes like the OEM one as that can throw your fitment off and I'd rather invest fitment hours on the part that REALLY counts, the intercooler area part.
This is a very good idea! I actually have 4 other designs, one of them doesn't even include the left side of the splitter, so it basically would just be the scoops, seal for the intercooler and a way to attach it.
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Old 02-15-2011, 03:06 PM   #12
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Quote:
Originally Posted by wrxdrvr View Post
I don't believe those vents are there to "cool" the turbo, I think it's there to let out, vent the hot air coming off from the turbo when stopped. JMO
Quote:
Originally Posted by MD04WRX View Post
Solution to cool the turbo with the stock spliter already exist.

http://www.subtle-solutions.com/prod...roducts_id=132

Quote:
Originally Posted by AWSnare View Post
Yes but as unibomber included in my other thread, this design can act as a chimney to guide the hot air out of the engine bay. While also directing the air toward the turbo moreso than the other splitters.
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Originally Posted by AWSnare View Post
This piece also ads another $180 on top of a splitter... I didn't know this existed either tho, I'm gonna look into it
Quote:
Originally Posted by wrxdrvr View Post
Again, I don't believe you actually need to cool the turbo... You actually want to keep the turbo hot (keep the heat in the turbo) but want to have a vent/chimney to let the heat that does come off from the turbo out of the engine compartment, to reduce heat soak of the TMIC...
Quote:
Originally Posted by AWSnare View Post
Valid point. I'm leaning toward my design that erases the left side of the splitter all together. So, I basically will be making a sealed splitter to the intercooler while leaving the left side completely open
Quote:
Originally Posted by teiva-boy View Post
Just make it cheaper than Subtle, and within reason of a JDM STi splitter, and you got my vote..

Oh, if you can make it height adjustable to some degree to account for different TMIC's, or bolting in an STi splitter into an FXT, than a single unit can work with multiple cars!
Quote:
Originally Posted by AWSnare View Post
It will be cheaper than subtle (they are only the chimney attachment anyways), and right around the same price as the jdm sti one. Ill prob have different molds for different seals too (bc of the different intercoolers)

-The first perfect splitter is going to utilize the sti tmic.
-Next will prob be the ebay tmic (only bc i want to try that intercooler to compare it to others)
-Then will be a spearco tmic since its apparently the biggest

As far as fitment on different years and different cars goes, Ill do my best to find people near me that have them (all years for the wrx/sti up to 07 are accounted for)

I merged my two threads together
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Old 02-15-2011, 05:10 PM   #13
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I think this is a pretty good idea, going to school for engineering myself, my knowledge of thermodynamics isn't as advanced yet but stuff like this is always what I've thought about, where in tristate are you? I'd be willing to loan my car for a little test fitting for the 08+ models, let me know and good luck
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Old 02-15-2011, 05:41 PM   #14
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I'm just wondering, the open portion that's the chimney right? I may have another idea for it that you might like
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Old 02-15-2011, 09:23 PM   #15
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Quote:
Originally Posted by icetc View Post
I think this is a pretty good idea, going to school for engineering myself, my knowledge of thermodynamics isn't as advanced yet but stuff like this is always what I've thought about, where in tristate are you? I'd be willing to loan my car for a little test fitting for the 08+ models, let me know and good luck
Quote:
Originally Posted by icetc View Post
I'm just wondering, the open portion that's the chimney right? I may have another idea for it that you might like
Currently Im in williamsport PA. I might need to find a 08+ wrx or sti... may take you up on that offer.

I have 4 other designs that I will post up in a bit.
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Old 02-15-2011, 10:09 PM   #16
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A shield that goes UNDER the TMIC would be the cats meow... bolted to the IC bracket and extended to be used as an extra turbo shield too as a chimney...
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Old 02-15-2011, 10:20 PM   #17
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Quote:
Originally Posted by wrxdrvr View Post
A shield that goes UNDER the TMIC would be the cats meow... bolted to the IC bracket and extended to be used as an extra turbo shield too as a chimney...
oooOOOOooooooo thats a good one!
that will require a lot more measuring haha
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Old 02-15-2011, 10:23 PM   #18
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would be interested in getting one for a perrin tmic
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Old 02-15-2011, 11:40 PM   #19
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I think because of all of the different intercoolers out there, I may end up just making a seal to fit the biggest intercooler I can get my hands on. Biggest I have seen (core size) is 20x7.5 so ill make an accordian style so it would fit
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Old 02-15-2011, 11:47 PM   #20
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Quote:
Originally Posted by wrxdrvr View Post
A shield that goes UNDER the TMIC would be the cats meow... bolted to the IC bracket and extended to be used as an extra turbo shield too as a chimney...

i've been considering the feasability of this for a while, something that directs the spent air down over the tranny housing and keeps rising heat from the engine off the intercooler. wouldn't have to even seal against the ic, just fit.

a nice ceramic spray and there would be nothing to heatsoak the ic. now if you sealed it and added fans..... plus, all the more reason to use that rear diffuser right? evac some more air from under the car?
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Old 02-16-2011, 12:36 AM   #21
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Well, I have 5 options of splitters I’m thinking of making. I’m going to use polycarbonate and eventually have carbon fiber ones.

I will also most likely be making
06-07 brake ducts (plastic and carbon)
Saggy butt spacers (1/4 and 3/8)
Rear bumper exhaust shields in carbon
Carbon canards
Din gauge mounts
CD player cover plates (for race applications)
Radiator shrouds (carbon or plastic (maybe even colored))
Alt/ps/ac cover (carbon or plastic or even colored plastic)

I’m still in the development stage for all of this... but I really want to start having product for sale around summer time

Ill have to work on a vendor account obviously, but let me know what you guys would be interested in! My aim is for quality parts at an affordable price!
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Old 02-18-2011, 02:04 AM   #22
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i was thinking a flap in the wall where the chimney and venting side meet with a gasket around it to seal it, when your driving the force of the air coming in would push open the vent allowing cool air to the turbo when your slowing down or idleing the flap will be closed and the air can escape through the chimney as normal
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Old 02-18-2011, 08:34 AM   #23
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Quote:
Originally Posted by icetc View Post
i was thinking a flap in the wall where the chimney and venting side meet with a gasket around it to seal it, when your driving the force of the air coming in would push open the vent allowing cool air to the turbo when your slowing down or idleing the flap will be closed and the air can escape through the chimney as normal
Im not sure I understand what you mean
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Old 02-18-2011, 11:19 AM   #24
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My intercooler from ebay is 20x8 I have yet to find a splitter that fits! New options would be great!
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Old 02-18-2011, 11:43 AM   #25
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I would be interested in getting on this as well for an 2004 STI. My degree is in mechanical engineering, so I will be glad to give some inout of needed.

The biggest bother is what others have listed - most solutions out there are too expensive and do not seal the intercooler = worthless. Good luck.
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