The air/water intercooler thead

[slowgenius]

Any updates on these builds?

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

[svynx]

-Nic-: How did you wire up the fans? Just on a switch or did you use a controler?

[Trudd84]

So does this setup have a stock radiator and a awic heat exchanger? Or does the exchanger, which from what I have gathered is mounted where the front mount goes, double as your cars radiator? I live in FL and this would be very beneficial, but I am just confused.

[ballitch]

Second heat exchanger just for the AWIC coolant. Yes, it goes in front of the radiator.


~Josh~

[Trudd84]

Ok, so If it is cooling the engine coolant, it is a radiator. if it is cooling the water within the AWIC, which is obviously a closed system, it's called the heat exchanger. I see. what does the inside of the top box that replaces the tmic look like? I understand that basically the reservoir holds water that is pumped into the core(?) which absorbs heat, is sent to the heat exchange to have the air movement help to relieve the water of its higher temperatures, and then returns back to the tank to get pumped again. the only thing the exchanger is doing is getting heat out of the water that was used to cool the air, correct. I am curious as to how the water and air pass through the top part(the thing that is in place of the tmic), curious as in the internal design. any links to pictures or a description?

[MFR Sweep]

This is basically what it looks like.

Originally Posted by Trudd84

Ok, so If it is cooling the engine coolant, it is a radiator. if it is cooling the water within the AWIC, which is obviously a closed system, it's called the heat exchanger. I see. what does the inside of the top box that replaces the tmic look like? I understand that basically the reservoir holds water that is pumped into the core(?) which absorbs heat, is sent to the heat exchange to have the air movement help to relieve the water of its higher temperatures, and then returns back to the tank to get pumped again. the only thing the exchanger is doing is getting heat out of the water that was used to cool the air, correct. I am curious as to how the water and air pass through the top part(the thing that is in place of the tmic), curious as in the internal design. any links to pictures or a description?

[Trudd84]

but obviously the water has a separate path from the air.

[MFR Sweep]

Yes.

Think of it if you welded a little box on either side of the current top mount where the air passes through. now you put a fitting on either side and pumped water through that.

That is your air to water intercooler. now that water gets hot. you pipe that to a heat exchanger (like a trans cooler but larger). That is basically another water to air system, but it is getting the heat out of the water.

Is that more clear?

[vicious_fishes]

how the front mounted intercooler rad currently sits:



because of the shape/size of it i was forced to choose between either using the stock plastic to duct it and lose some of the surface area, or chop the hell out of the bumper and duct it myself to ensure the whole surface area gets fresh air - i opted to chop the hell out of the bumper. you can see the hole to the left that shows where the big black part of the bumper used to be - fairly significant amount of the rad being cut off from airflow. probably nearly doubled the surface area chopping it out.


i've still got to duct it and i've since worked out a way i can run it a little lower, so i'll get plenty more happy snaps when i get around to that. i'm currently housebound sick as a dog with man flu so not sure when that will be. i'll get plenty of snaps of how i mounted it too.


i too am running the following combo:



nice fat 3.5 inch thick core:


dunno about you but i just ordered the biggest rad on the site.

[WhatTurboLag?]

Has anyone used hydraulic quick disconnects on the intercooler hose to make it a LOT easier to remove the intercooler without needing to re fill the system?

[vicious_fishes]

i used standard hose clamps. 10 seconds with a screwdriver and they're off.


why would you need to remove the intercooler?

[WhatTurboLag?]

To do work on it lol, I don't want to have to take it off and have it dangling there by hoses

[vica153]

We need to find a new source for AWICs, these tiny ones off frozenboost are no where near the proper size and they want way too much for the big ones.

[svynx]

^ What do you mean tiny? There are a number of large ones for sale. Plus, you have to consider that these do a better job than air to air coolers, which means they can be smaller, which plays into them not having large coolers...cause they don't need them.

[vica153]

They're too small to properly cool the intake air at higher rpms (+4000). I've tested the type 14 and a good FMIC provides better cooling up top.

I like the idea of an AWIC. I ran the JDM Legacy AWIC on my last swap. TMIC boost curve without needing a hood scoop and the ability to run sub ambient water temps, but it's hard to find a good AWIC for a decent price.

I think a good TMIC w/water sprayer setup would outperform these AWICS. I thought about welding 2 of the type 14s together. I might try it this winter.

[vicious_fishes]

my water/air setup was about 2/3rds the price of a decent FMIC kit.

also you can run more than one intercooler much easier this way. if you've got a straight point in your piping, stick a barrell WTA cooler there.

[DeleriousZ]

Great thread guys, keep this one fresh and updated!!

[hybrid gti 2]

This thread has potential

[vicious_fishes]

taking mine for a right royal thrash the intercooler itself is still very cold to the touch. charge pipe is quite warm, so i'd say it's working

how i mounted it initially:


as you can see that's not all that lined up - since lined it up properly and lowered it to look like the following:


though i'm not sure if that's an after pic now i look at it

will get some more snaps up this week. my car is a work in progress.

[svynx]

Looks good vicious. I've trashed mine enough to have the top part of the core very warm, but the bottom part (both next to the throttle body and the part next to the turbo) was nice and cold. Have fun with it.

[vica153]

Log intake temps. You have a big heat exchanger up front and small intercooler, of course it isn't going to get hot. That doesn't mean it is doing a good job pulling heat out of the intake charge.

Speaking of thrashing/trashing, even after being rear ended and the radiator push into the crank pulley my AWIC setup didn't leak at all. A perk over an FMIC if you have a tendency to bash into things.

[draco159]

Anyone doing these with a rotated setup? Can't view the pics at work so I can't check now.

[svynx]

Vica: without spending money on a dedicated heat sensor, and finding a place to install it at/near the throttle body, it would be very hard to get that info. Yes, the APv2 does have intake temp capability, but that's at the MAF, which wouldn't help.

Draco: Yes, I'd have to look back through, but I believe there is a pic here of one.

[vicious_fishes]

Originally Posted by vica153

Log intake temps. You have a big heat exchanger up front and small intercooler, of course it isn't going to get hot. That doesn't mean it is doing a good job pulling heat out of the intake charge.

Speaking of thrashing/trashing, even after being rear ended and the radiator push into the crank pulley my AWIC setup didn't leak at all. A perk over an FMIC if you have a tendency to bash into things.

well yeah but i mean the intercooler being cold is still much better than it being hot yeah?

i would have thought if it was doing a **** job then the hot air would heat it up?

[jstn]

Originally Posted by vica153

We need to find a new source for AWICs, these tiny ones off frozenboost are no where near the proper size and they want way too much for the big ones.

hey guys,

i found this thread searching for heat exchanger info. admittedly, im a VW tdi geek, but im also designing an awic setup for my gtb1756vk turbo swap (28psi tune).

im having Bell Intercoolers (www.bellintercoolers.com) make me a custom awic and reservoir, which will sit where the battery was (relocated to trunk). ive spec'd a 6x6x7.5" core, and with the end tanks should provide about enough space for a 1/2 gallon reservoir. roughly speaking, this will all fit in the space formerly occupied by the battery (maybe an inch taller and 2 inches longer).

id highly, highly recommend calling them and chatting about your application. they're super knowledgable and willing to help. don't forget to buy corky bell's book on turbo charging!

stay cool,

justin