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Old 07-26-2001, 10:43 PM   #1
Blugin
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Default How to make an intercooler sprayer for the WRX for under 40 bucks!

.
>>note->copy&paste links into address bar to see pics<<
.
Ok, I've gotten my act together, gotten my pics together and am ready to tell you guys how I made my intercooler sprayer.
Ok, first of all, my system is manually operated, but a hop switch that will operate the system under boost can be fitted, as can an aftermarket "brain" for these things. Second, this thing came to about $38 total- so it's a cheap mod. Third, you might not notice any power gain, but for the summer, or the racetrack, this is a good mod to boost intercooler efficency.
you will need:
1/4" tubing- several ft (Home Depot plumbing)

http://albums.photopoint.com/j/View?...nce=0&res=high
.
9/64x5/32" soft vacuum elbow- 4 (auto parts store)
http://albums.photopoint.com/j/View?...nce=0&res=high
.
washer pump, wiring clip and rubber grommet from washer bottle (nissan or subaru)-1 (junkyard) get one
that looks like this- (this one was from an '89 Nissan 240sx)

http://albums.photopoint.com/j/View?...nce=0&res=high
.
switch of preference- 1(Radio Shack)

http://albums.photopoint.com/j/View?...nce=0&res=high
.
Arizona mist replacement nozzles- 4(Home Depot)

http://albums.photopoint.com/j/View?...nce=0&res=high
.
5/32" vacuum tees- 3 (auto parts store)
wire- several ft
zip ties
super glue
silicone sealer
scissors
wire strippers
drill with bits
anything else you can think of that would help
.
.
.
Drain the washer fluid resovior and remove the top two bolts that hold it in place. Take the biggest drill bit you can find (I used 1/2") and drill out the plug looking thing in the recess where the pump will go. Widen the hole evenly with the bit until it is large enough to accomodate the grommet from the new pump snugly. Rinse out the bottle thoroughly because drill shavings will clog the sprayers easily. Seal the grommet into the hole with silicone. Seal the pump into the grommet with silicone. If you have a wagon you will probably need to find a different spot for the pump or you can just use the rear washer pump. Here's how mine looked when the new pump was installed.
http://albums.photopoint.com/j/View?...nce=0&res=high
.
With the washer bottle out you can now wire your pump to your switch using the hole in the firewall between the clutch and brake pedals. I will leave the details out of this because you might want to do a custom switch in a different location or do a boost sensitive switch.
Reattach the bottle. Now break out the drill and drill a 1/4" hole in each of the depressions under the hood scoop (this is where the STi model sprayers are)- you should refer to the picture below if you cant find these. Assemble the spray nozzles to look like this using 2 brass nozzles, 2 rubber elbows and 1 vacuum tee in each (leave unglued):

http://albums.photopoint.com/j/View?...nce=0&res=high
http://albums.photopoint.com/j/View?...nce=0&res=high
.
Now you can use the pic below to see how to do the tube routing.
I attached the main tube to the underside of the hood using zip ties- take one zip tie and make a ring about 1" in diameter. Now take another zip tie and wrap it a round the tube and into the first ring and lock it snug (never tighten zip ties around the tubes too tight) You should have a ziptie mini-chain with the tube attached. Now you can push the 1" ring through the hole already drilled under the hoodscoop and it will hold the tube.
Time to fit the hoses. Make it look like the pic below.
http://albums.photopoint.com/j/View?...nce=0&res=high
.
Here's a tip: use Super Glue to attach the clear hoses to the tees and pump or they will blow off from the pressure, but do not glue the black elbows to the tees when assembling the nozzles because you will not be able to aim them up and down(they will not blow off anyway). One last tip: when you have the shorter tubes hanging down through the holes in the scoop aim the nozzles where you want them to spray (left to right) and have a friend hold them. Once you glue the two short tubes to the tee junction, the position they are glued in determine where they aim left to right. Now you should be ready to go. Just aim the nozzles up and down where you want them to spray, my two center ones are aimed a little higher than the two outer ones. I will do a test by placing a sheet of paper over the intercooler closing the hood going about 40mph (no boost) and turning them on briefly. This should show the area covered clearly.
Hope you enjoyed my ittle How-To Feel free to add any specific questions or comments!
P.S. it looks like Photopoint wont let me host pics outside their site- so I changed them to links- sorry for the inconvienence. If anyone knows where I can host pics plese tell me!
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Last edited by Blugin; 07-27-2001 at 01:17 AM.
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Old 07-27-2001, 12:10 AM   #2
wigglesxjr
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Blugin, thanks for the info. It may be something i'll want to do given a weekend. right now i'm deciding between the efficacy of the Injen CAI or an intercooler sprayer system...

-Joseph Tan
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Old 07-27-2001, 01:04 AM   #3
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WOW!

Great writeup man!
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Old 07-27-2001, 01:55 AM   #4
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Wonderfull information. Thanks, I was wanting to do something like this. Maybe you could mount windshield sprayer heads in that same position, you can aim those easily. That might be too much water though. Great job, looks like a clean install!
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Old 07-27-2001, 09:15 AM   #5
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Thanks bud!! No lucks viewing the pics though!

Jorge (RiftsWRX)
www.ProjectWRX.com
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Old 07-27-2001, 09:32 AM   #6
westy66
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yea man.....
i cant see 'em either

Bob
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Old 07-27-2001, 09:44 AM   #7
8Complex

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You gotta copy the link, then paste it into one of the windows that you got the "photo unavailable" pic in. Photopoint is a PITA when it comes to linking, obviously.
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Old 07-27-2001, 10:58 AM   #8
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Do you have any pictures of the spray heads on the inside of the scoop (where they sit)? If you could post them. Thanks for the write up, gonna have to build myself a water spray kit this weekend.


Russ
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Old 07-27-2001, 11:08 AM   #9
RiftsWRX
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Blugin, you opposed to me taking your write up and pics and hosting the install on my site? Giving credit to you of course.

Jorge (RiftsWRX)
www.ProjectWRX.com
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Old 07-27-2001, 11:17 AM   #10
RiftsWRX
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I'm actually going to take a small twist to your project in my implementation.

http://www.jcwhitney.com/product.jht...=14950&BQ=jcw2

I'm going to measure space, but I'm thinking I'll go with the horizontal or flexible tank and use that for a dedicated supply for my car. JC Whitney is actually about a half hour from me, so I'll pick one up and take a look.

Jorge (RiftsWRX)
www.ProjectWRX.com
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Old 07-27-2001, 01:03 PM   #11
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Thanks for all the comments guys!

SuperFreq: I thought about the windshield sprayer heads, buy they dont shoot a fine mist, they just squirt water. You need the largest amount of finest mist possible for max. cooling and the spray heads I designed do the trick nicely. You can modify the design to incorporate more spray nozzles if needed.

WRX1: I tried taking pics of the sprayers in the hoodscoop and I couldn't figure out how to position the camera to take a good pic. I'll try again tonight.

RiftsWRX: I am not opposed at all to you taking my write-up for your site if you give me credit. I consider it a compliment. Are you going to mount the tank in the trunk? I plan on doing this much later on.

keep em comin'.
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Old 07-27-2001, 03:11 PM   #12
RiftsWRX
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Cool! Well I have the kit in front of me.. the bottle is tiny enough where I'm going to find a place under the hood to mount it. For now I'm going to use the stock spray nozzles that come with it (I know I know) but I wanna get the OEM STI nozzles.. those work REALLY nice.

I think I should work on it this afternoon. But we'll see I gotta lot to do for my trip to spain next week.

Jorge (RiftsWRX)
www.ProjectWRX.com
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Old 07-27-2001, 04:01 PM   #13
Blugin
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The only problem I think you'll have is that you will be refilling that thing all the time. The stock washer bottle holds about 2 gal. and it seems to empty rather quickly with my tiny spray nozzles.
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Old 07-27-2001, 04:30 PM   #14
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Ingenious. That's soo trick! Can we do this w/ a nos system integrated?
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Old 07-28-2001, 03:56 PM   #15
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bump
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Old 08-29-2001, 05:50 PM   #16
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Free bump for you Blugin!

The write up is done and posted on my site. Under DIY Mods


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Old 08-29-2001, 06:16 PM   #17
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Default re-picture hosting

I switched over to printroom.com

free photo hosting and you can link your pics

Hope this helps
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Old 08-29-2001, 08:52 PM   #18
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Blugin - i sent you an PM and email and got no reply - i spent 3 hours looking all over the home depot store trying to find those arizona mist replacement nozzels - can you give us some more info on them ??? Which section are they in - what do they do - do you have a sku on them

Thanks - AL
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Old 08-29-2001, 11:09 PM   #19
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Al,

If you go to www.projectwrx.com, look in Jorge's DIY Mods section, scroll down to the bottom, he has Arizona Mist's site Hyperlinked. That's how I found their website. Anyway, their info is: Phone # (480)966-MIST (6478), toll free at 888-567-MIST (6478), via fax at (480)838-2232, or USPS at 1051 N Fiesta, Gilbert, Arizona, 85233.

I think she said they only sell packs of 5 nozzles, and it came to like $11 with shipping, said it should be here by Friday.
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Old 08-29-2001, 11:18 PM   #20
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Austin - you da man - thanks - - soon I'll be spraying h20 also !!
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Old 08-30-2001, 12:08 AM   #21
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Do you guys have any idea what kind of improvements these will get you?

For instance, will it help in the 1/4th mile? Will it knock off 1/10th of a second or something?

Also, I would think it would freeze up in winter if yoju use water, so be sure to drain the thing before it gets cold outside!
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Old 08-30-2001, 12:20 AM   #22
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some people add alchohol to the water as a anti-freeze
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Old 08-30-2001, 12:52 AM   #23
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What is I-club time out?
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Old 08-30-2001, 07:35 AM   #24
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Just use windshield wiper fluid. The low alcohol content will actually help cool it down further but not enough to the point of igniting... plus you'll have a really clean intercooler, which will further help the cooling process.

Jorge (RiftsWRX)
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Old 08-30-2001, 08:44 AM   #25
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What all is in that magic blue fluid anyway?
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