The air/water intercooler thead

[Krang]

Update on mine now that it's complete.













New tune optimized for the AWIC, we were about an hour into the session at this point and had some issues with the car getting too hot and pulling timing. I'm going to work on some ways to combat that, but overall I'm very happy with the small improvements. I was hoping for some more HP but I think that some cooling improvements and some octane will take care of that. Feels a lot smoother too for some reason, I think the AVCS is doing more work now. Probably going to try and secure a 55gal drum of e98 and mix a blend for the next go around, the 92 oct here really hampers what we can do for the most part.

Still, very safe tune so I can beat it to hell and it will stay in one piece.

300wtq @ 3k rpm!

Overlay of the baseline I had done with the frontmount (RED) and the AWIC (BLUE):


Here is a vf39 just about maxed out w/ Meth for comparison:

More info on the vf39 here: Adam's VF39 Meth tune...TORRRRQUEEE! - NASIOC

* Registered users of the site do not see these ads.

[AudioRuso]

Hell yeah! Well done! I wish I had some room in my trunk for that setup but I need the spare since I regularly drive over a mountain pass and the spare is pretty essential. The heat exchanger at the front looks very clean too!

[TeddyK]

The AWIC setup saturated?? Odd.... Hose kink? Air bubble in the Core?

Nice setup BTW! I like the -AN fittings; nicely done.

[Legacy_H6TT]

Did you know that the first generation Legacy GT had a water to air intercooler as standard...? Was pretty efficient with the front mounted radiator!

[gtt]

Hi all,
Great thread! Ive looked and looked for W2A forums but no luck, I've gone from the start to finish reading all of this and great info.
I definitely know my issue.
Ive a type 14 W2A IC running 27psi boost and my tuner says its heating up bad, as you can see from my dyno runs i made 347hp at 24 psi and IAT was just below 50 degrees Celsius then at 27psi it sky rocketed to 70 degrees only making another 6 hp but did make a little over 80NM more torque.
I run a SR55 turbo thats been rebuilt with a Garrett gtx3076r char, Ive got a vortex tank in the back, a decent size heater exchange and also have killer chiller.
I live down here in Australia.
Ive got a few ideas on new IC I'm going to put into it but any thoughts? its in a RS liberty or as you say 1st gen legacy.

[gtt]

How to insert images only links?

[AudioRuso]

Stupid question but are you measuring temps before or after the intercooler. Also, any chance you're at your turbo's upper efficiency range?

Both are probably no but I was curious.

[gtt]

Originally Posted by AudioRuso

Stupid question but are you measuring temps before or after the intercooler. Also, any chance you're at your turbo's upper efficiency range?

Both are probably no but I was curious.

The temps are are taken on the throttle body as I run my map sensor there for the ecu, the turbo @27psi is it most efficient range, well meant to be.
Thanks

[TeddyK]

Originally Posted by gtt

Hi all,
Great thread! Ive looked and looked for W2A forums but no luck, I've gone from the start to finish reading all of this and great info.
I definitely know my issue.
Ive a type 14 W2A IC running 27psi boost and my tuner says its heating up bad, as you can see from my dyno runs i made 347hp at 24 psi and IAT was just below 50 degrees Celsius then at 27psi it sky rocketed to 70 degrees only making another 6 hp but did make a little over 80NM more torque.
I run a SR55 turbo thats been rebuilt with a Garrett gtx3076r char, Ive got a vortex tank in the back, a decent size heater exchange and also have killer chiller.
I live down here in Australia.
Ive got a few ideas on new IC I'm going to put into it but any thoughts? its in a RS liberty or as you say 1st gen legacy.

With the AWIC Type 14 it has only 1/2" NPT which the true ID isn't very large. That always worried me a bit on some of these setups, in mine all of my connections of the 3/4" variety. With such a small hose a flow restriction will be greater in a sense. Have you measured the actual flow rate? And versus what the pump can actually do?

[gtt]

Originally Posted by TeddyK

With the AWIC Type 14 it has only 1/2" NPT which the true ID isn't very large. That always worried me a bit on some of these setups, in mine all of my connections of the 3/4" variety. With such a small hose a flow restriction will be greater in a sense. Have you measured the actual flow rate? And versus what the pump can actually do?

Yes thats good thinking as I've never thought of that, it seems to flow pretty good, i run a bosch pump, ill double check it though.

[gtt]

[Krang]

Originally Posted by TeddyK

The AWIC setup saturated?? Odd.... Hose kink? Air bubble in the Core?

Nice setup BTW! I like the -AN fittings; nicely done.

Coolant was getting hot, not the AWIC. It stayed quite cool.

[wrxhard]

Bump. Refusal to let this thread cycle out of existence.

[AudioRuso]

Ok, I'll add to it. I blew my motor and had a long month to work on random stuff while waiting for my new IAG Stage 2 block.

I added 90 degree elbows to my hoses all over to remove kinks and did a paint job on my heat exchanger.

Very satisfied right now

[TeddyK]

Very Nice AudioRuso! I also like what you did with your EWG.

Also, this week my mechanic will finish the turbo upgrade and AWIC install; when I do the drivetrain I will send out my heat exchanger and water core assembly to get anodized in gold color.

[AudioRuso]

Originally Posted by TeddyK

Very Nice AudioRuso! I also like what you did with your EWG.

Also, this week my mechanic will finish the turbo upgrade and AWIC install; when I do the drivetrain I will send out my heat exchanger and water core assembly to get anodized in gold color.

Yes sir, I actually just started a build thread yesterday.
http://www.wrxtuners.com/forums/f281/loxxy-budget-built-08-wrx-unique-custom-fabrication-74682/

[TeddyK]

Great write up.

I saw your blog awhile back that helped me with some decisions on my project.

Didn't know you did glass sculptures very nice!

[Underdog_LGT]

Originally Posted by Shadow27AU

Type 14 core, Davies Craig 150l/h pump. Something wrong with your setup. Never saw iat over 38c, 26+ psi through Dom 1.5 7cm on EJ207.

Clean install! Any other details about the setup? The charge pipe and BPV are the best looking I've seen for Type 14 installs. Is that a factory turbo coolant reservoir for the AWIC by the shock tower in the top right, along with the KillerB dual reservoir tank?

I also have a Dom1.5XTR twinscroll and am looking to optimize the intercooling without the downsides of FMIC. When I built this current iteration for my Legacy Grimmspeed had not yet released the LGT/WRX TMIC and the PW was difficult to find, so I decided to give the '08+ STI TMIC a try. I figured I was going to be running a relatively mild tune for 93 octane at first, and the intercooling requirements could grow as did my fueling options (leaning towards meth).

Currently looking for places to tap-in 3bar Bosch TMAP sensors pre and post-IC without drilling & tapping the end tanks, but the TMAPs are made to bolt down to a flat metal surface and require reasonable tolerances to seal the o-ring, which means the end tank is ideal. With the Type 14 can you get enough space between the IC outlet and throttle body flange to fit a 1/8NPT port (like this) or a 1/2NPT (like this) to the silicone coupler? Or will the TMIC be jammed up against the firewall? If it's possible I could just run two of those bungs and have individual IAT and pressure sensors. After testing, the bungs could be re-purposed for meth, or plugged, or the coupler could be swapped out on the cheap. If not I'll just have to drill some holes in a perfectly good TMIC.

[Titter]

whats everyone using for coolant lines to their heat exchanger/radiator?

would -8 be enough? or should i go with -10?

i ask because i have a ton of -8 fittings and hoses but no -10 stuff. not that i cant get -10 stuff, but i already have -8 stuff so it wont be an extra cost.

thinking of the Type 14 core to cool an approximate 500hp setup. 317Gph Bosch pump. Debating a Type 101 or Type 118 Heat exchanger. will -8 flow enough for this setup you think?

[AudioRuso]

Hey titter, I don't know what those numbers mean but I can tell you that my hoses are 5/8 ID. This is around the size of the inlet/outlet on the pump (It's a VERY tight fit).

To avoid any kinks in the lines I used 90 degree bends that I painted to look nice (I got about 8 copper elbows that were 1/2" but they are measured in nominal so they are exact same ID as the hose and although it's a tight stretch, the hose does go on (with a clamp of course).

I also ported the larger fittings that go onto the heat exchanger and water to air intercooler. They were 5/8 OD but pretty thick brass. I simply stuck them in my wood lathe and used drill bits sequentially to bore them out as big as I could, and then used a very narrow tool to open up the tip (so it's a nice and smooth/gradual... or lofted if you will.. approach on both sides).

[omiotek]

Originally Posted by Titter

whats everyone using for coolant lines to their heat exchanger/radiator?

would -8 be enough? or should i go with -10?

i ask because i have a ton of -8 fittings and hoses but no -10 stuff. not that i cant get -10 stuff, but i already have -8 stuff so it wont be an extra cost.

thinking of the Type 14 core to cool an approximate 500hp setup. 317Gph Bosch pump. Debating a Type 101 or Type 118 Heat exchanger. will -8 flow enough for this setup you think?

-10 is thr way to go

[Krang]

I went with -12an everywhere I could, but had to use -10an on the heat exchanger.

In the future I will probably add another type 101 exchanger and Y the -12 into two -10 fittings and run them parallel to slow down the flow through the heat exchanger part of the system and get better overall cooling.

[Titter]

appreciate the responses all ty.

i guess -10 it is, if not bigger.

[Titter]

is too much flow from the pump a bad thing?

im considering the bosch cobra pump as an upgrade for reliability. the base pump offered in the frozenboost kits looks really low quality.

problem is the cobra pump flows 314 gallons per hour while i see most ppl here running 200-300 litres per hour tops.

will this be an issue?

[AudioRuso]

I don't think it will be a problem as long as your hoses are the same size as pump and you have no reductions or kinks so everything flows open not putting a strain on the pump.