VCP Air to Water Intercooler kit

[Wayne Presley]

The kit is finalized and ready for orders. Comes complete with all the T-bolt clamps, Bosch water pump, large heat exchanger, fittings, hose clamps, BOV/BPV, coolant hose and intercooler core. The AWIC will give lower intake temps than the stock air to air intercooler. $1400 plus shipping.

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818-build%201/P1020975_zps6ca66aac.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/818-build%201/P1020975_zps6ca66aac.jpg.html)

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818-build%201/P1020974_zpsca11d48e.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/818-build%201/P1020974_zpsca11d48e.jpg.html)

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/P1020634_zps6a62a346.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/P1020634_zps6a62a346.jpg.html)

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818-build%201/P1020977_zpsb917018e.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/818-build%201/P1020977_zpsb917018e.jpg.html)

IC core bleed valve installed. Allows you to make sure there is no trapped air in the IC core. Simply run the pump and loossen bleeder until coolant comes out then close bleeder. Top off radiator.

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/P1030049_zpse31dd920.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/P1030049_zpse31dd920.jpg.html)

Tool less bleed valve option (Add $10)

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818-build%201/P1030050_zps56afa275.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/818-build%201/P1030050_zps56afa275.jpg.html)

[Santiago]

That's a solid deal. I took some time to pretty meticulously spec out a complete system very similar to this and didn't come up with much of a savings. Plus, to do it I'd still have to get the bit of custom work done on the tubes. Save the time. Get the kit. From Wayne. With your money.

(Sorry I'm on a JSP kick today.) =)

Best,
-j

[07FIREBLADE]

Looking at the pics. Where is the bov mounted. And is there an option for the dual exchangers like on eriks

[Wayne Presley]

The BOV is an option and can be mounted on the tube underneath or on the end of the IC core. Dual heat exchangers would be available at additional cost and you would have to fabricate the mounts.

[bompus]

Looks beautiful. I already have this on order along with some other goodies. Great job Wayne.

[K3LAG]

Wayne,
It looks like you redesigned the position and mounting of the intercooler to take up less space. Does it leave room for a trunk now?

Larry

[Wayne Presley]

It allows for the trunk now, one of the reasons for the redesign over what's in my car.

[K3LAG]

That makes it really tempting. It looks like the orange stickers and plumbing might even almost match my car ;-)

Larry

[Wayne Presley]

Well the sticker is orange but the silicone is red, the camera sucks at red variations. I took pics of the floor mats and the near one face on looks yellow and the other side off center looks the correct orange.

[07FIREBLADE]

Wayne for this setup is there no fan for the heat exchanger. By the looks of it there isn't. Is it just setup to use the radiator fan to creat suction through both exchangers? And is the pump the Bosch pump that comes on the cobras?

[Wayne Presley]

You can put side skirts between the heat exchanger and radiator to use the radiator fans. I don't think they are needed as there is no significant intake heating while the car is stationary, there is plenty of coolant volume and as soon as the car gets rolling there will be plenty of air flow. We run a 20% smaller heat exchanger on the SC Lotus and IC water temps after a 30 minute race average 115° F with no fans. It is the same pump that is on the SVT Cobra and Lightning F-150's.

[nkw8181]

Dang you Wayne my budget keeps going up because of people like making awesome things that I "need". I'm just prioritizing what I need first. Keep up the good work. Oh I really like that you made it so we can can have a trunk (even if it is small).

[07FIREBLADE]

Trunk will be the same size as if you were using the stock tmic. Thanks for the info on the awic. When budget permits I'll be in touch. Just wanted to do my research.

[Xusia]

Yeah. I haven't yet decided what to do as far as an intercooler solution, and since this allows for a trunk and requires no engine compartment airflow, I just might spring for it.

[Wayne Presley]

Here are pics of the plumb back option TurboSmart bypass valve.

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/P1020711_zpsb405cff9.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/P1020711_zpsb405cff9.jpg.html)

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/P1020710_zps3d1bc947.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/P1020710_zps3d1bc947.jpg.html)


Here is the straight blow off TurboSmart valve version (available blue and black).

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/P1020653_zps85b39c28.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/P1020653_zps85b39c28.jpg.html)


Either valve is a $200 option to the AWIC kit price.

[Doowop]

Wayne,

any numbers on the temp difference between that setup and a regular IC? what about weight? thanks

[Wayne Presley]

In cruise driving the stock air to air was showing 35°F over ambient, with the AWIC blasting around it was showing 8°F above. Huge difference in cooling. I'd say it weighs 18-20 lbs more than the stock 02-05 IC.

[Santiago]

Wayne, is a reservoir included as well? I didn't see it in the list of what's included but I thought you were originally offering it in the kit and you mentioned coolant volume, so I thought I'd ask.

Even if it is not included, any thoughts on what sort of performance level/demands would make one appealing in our application? For ex: typical use of an 818R vs 818S?

Thanks!

Best,
-j

[Doowop]

Wayne, could you be a little more details on how everything mounts, where the pump goes, what it looks like? Do you have pictures of the full install? Where do you run the hoses to the front heat exchanger? thanks

[Wayne Presley]

The pump mounts up front by the battery and is a Bosch pump. The hoses run down the side of the car by the coolant tubes and go to the drivers side of the heat exchanger. The pic in the first post shows the mounting of the heat exchanger and the outlet ports.

[Wayne Presley]

Wayne, is a reservoir included as well? I didn't see it in the list of what's included but I thought you were originally offering it in the kit and you mentioned coolant volume, so I thought I'd ask.

Even if it is not included, any thoughts on what sort of performance level/demands would make one appealing in our application? For ex: typical use of an 818R vs 818S?

Thanks!

Best,
-j

It works so much better than the stock air to air even on a base 2.0 build. Add HP and that adds heat to the charge and it becomes even more important. I changed heat exchangers which deleted the need for a reservoir since the volume doubled and has a radiator cap.

[Hindsight]

I'd say it weighs 18-20 lbs more than the stock 02-05 IC.

Wayne, is 18-20lbs the difference between the stock IC and this IC only, or does it include the weight of the front mounted heat exchanger + hoses to it and pump and water? How many gallons does it hold?

Thanks

[Wayne Presley]

I would say it holds about 2 gallons of coolant. I would say the IC themselves weigh about the same and the extra weight is in the HE, pump and hoses.

[Hindsight]

Nice, 20lbs is a very, very small price to pay for the increase in cooling performance, I feel.

[Frank818]

Looks like Wayne has updated his website! Pretty cool! It's animated now! :)

http://www.verycoolparts.com/

[bompus]

Hey Wayne,

Would you be able to provide some install instructions for all those that may be interested? I'm curious because I've seen others use a separate reservoir, but not sure if that is required or not. A step-by-step would make the install easy to understand for all and might even lead to more sales :)

[Wayne Presley]

Here is the heat exchanger mounting
Put fittings and mounts on as shown with supplied hardware, leave mounts loose.

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818-build%201/P1020903_zps78fe1e30.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/818-build%201/P1020903_zps78fe1e30.jpg.html)

Place the HE in front of the radiator with the brackets using supplied Rivnuts and brackets.

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818-build%201/P1020904_zpscf13a7e7.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/818-build%201/P1020904_zpscf13a7e7.jpg.html)

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818-build%201/P1020905_zpsff9e1a8a.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/818-build%201/P1020905_zpsff9e1a8a.jpg.html)

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818-build%201/P1020906_zps00949cad.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/818-build%201/P1020906_zps00949cad.jpg.html)

Mount the IC coolant pump behind the battery with supplied mount

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818-build%201/P1020922_zps1ee0ec7b.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/818-build%201/P1020922_zps1ee0ec7b.jpg.html)

run hoses to the rear, clamp along the frame

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818-build%201/P1020924_zps2c40dc1d.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/818-build%201/P1020924_zps2c40dc1d.jpg.html)

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818-build%201/P1020923_zps567d0367.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/818-build%201/P1020923_zps567d0367.jpg.html)

[Wayne Presley]

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818-build%201/P1020920_zps24558cf3.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/818-build%201/P1020920_zps24558cf3.jpg.html)

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818-build%201/P1020921_zpseef5dbd4.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/818-build%201/P1020921_zpseef5dbd4.jpg.html)

Loosely bolts in both front IC mounts on the block. Put the 45° 2" silicone hose on the outlet of turbo with supplied T bolt clamp and insert BOV/BPV pipe, connect BPV hose to BPV if applicable. Put the 45° 2.75 to 3" adapter on the throttle body. Put the coolant hose fittings on the IC, 90° on drivers side. Install IC using the front mounts already in place, and loosely place Tbolt clamps on the throttle body silicone.

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818-build%201/P1020975_zps6ca66aac.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/818-build%201/P1020975_zps6ca66aac.jpg.html)

Install rear mount, 02-04 mount shown.

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818-build%201/P1020976_zps35d50fbd.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/818-build%201/P1020976_zps35d50fbd.jpg.html)

Put the 90° silicone on the BOV/BPV tube, use the 6" aluminum coupler to the 90° adapter to the IC.

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818-build%201/P1020974_zpsca11d48e.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/818-build%201/P1020974_zpsca11d48e.jpg.html)

[nkw8181]

nice! can't pull the trigger on this yet but working on the budget to me it so :)

[bompus]

Wayne, do you recommend an overflow tank in front and back then? If so, do you just hook lines up from both the radiator and heat exchanger to the front overflow?

[Frank818]

The hoses run down the side of the car by the coolant tubes and go to the drivers side of the heat exchanger.

What I was looking for, couldn't tell if there was enough space by the sides as I don't have mounted the body panels yet.

[Wayne Presley]

Wayne, do you recommend an overflow tank in front and back then? If so, do you just hook lines up from both the radiator and heat exchanger to the front overflow?
The HE will need a small overflow. For the engine cooling system, I much prefer a single coolant recovery tank in the back. Put a higher pressure cap up front and cap/plug the recovery tube.


What I was looking for, couldn't tell if there was enough space by the sides as I don't have mounted the body panels yet.
There is room down the sides as I've had the sides on this car after installation of the system.

[bbjones121]

Does this protrude into trunk space much? If so, is there any other configuration that wouldn't?

[Wayne Presley]

Does this protrude into trunk space much? If so, is there any other configuration that wouldn't?

It does not intrude into the trunk space

[bbjones121]

Awesome! Any photos of top view showing how far back it goes? Or side.

[Wayne Presley]

The trunk opening is just over 6" past the cross brace, the intercooler extends just under 6" past brace.

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818-build%201/P1020999_zps8774989f.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/818-build%201/P1020999_zps8774989f.jpg.html)

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818-build%201/P1020997_zps1bfc0a94.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/818-build%201/P1020997_zps1bfc0a94.jpg.html)

[bbjones121]

thank you for all the pic.

[Frank818]

Here is the heat exchanger mounting

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818-build%201/P1020903_zps78fe1e30.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/818-build%201/P1020903_zps78fe1e30.jpg.html)

What are the size specs of this HE again? I see it's the one metalmaker got, I look for something similar to that. It's nice that it has already the mounts, so if I like the size and price, I might be a buyer. For the HE alone, though.

[Wayne Presley]

I was on the dyno today with an 818 with my AWIC on it and it works awesome! It was hot here today, 94°F and after 20 pulls on the dyno, the manifold air temp went up from 94 to 102°. That's pull after pull after pull. The most temp increase during any single run was 1°.

[Sgt.Gator]

And no Dyno results? Curiosity !

[Frank818]

I was on the dyno today with an 818 with my AWIC on it and it works awesome! It was hot here today, 94°F and after 20 pulls on the dyno, the manifold air temp went up from 94 to 102°. That's pull after pull after pull. The most temp increase during any single run was 1°.

Not surprised at all! Wayne have you ever tried different HEs on the same setup, to see which one was most efficient? Thin large frontal vs thick small frontal, as example.

[Wayne Presley]

This motor made 364 RWHP and 380 TQ

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818-build%201/20140905_183737_zpsefe6473e.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/818-build%201/20140905_183737_zpsefe6473e.jpg.html)

[Wayne Presley]

Not surprised at all! Wayne have you ever tried different HEs on the same setup, to see which one was most efficient? Thin large frontal vs thick small frontal, as example.
Large front works the best as the radiator fans do a very nice job of pulling air through both cores. i've got the wide thick HE in my car and it works well but not like the big one.

[Hindsight]

This motor made 364 RWHP and 380 TQ

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818-build%201/20140905_183737_zpsefe6473e.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/818-build%201/20140905_183737_zpsefe6473e.jpg.html)

Nice, what are the specs?

[mekohler]

The VCP AWIC is very nice, easy install and Wayne is great to deal with. It is obvious that Wayne put some thought into this. Thanks Wayne.

[Wayne Presley]

Nice, what are the specs?
STI block crank and rods, 2.0 heads, ARP studs, ported heads, 23 psi from a Blouch 2.5XT turbo, VCP AWIC, JE pistons, 1000cc injectors


The VCP AWIC is very nice, easy install and Wayne is great to deal with. It is obvious that Wayne put some thought into this. Thanks Wayne.
Thanks Matthew

[Hindsight]

Thanks Wayne, that sounds very much like the build I had in mind.

[STiPWRD]

STI block crank and rods, 2.0 heads, ARP studs, ported heads, 23 psi from a Blouch 2.5XT turbo, VCP AWIC, JE pistons, 1000cc injectors
Ditto, that's the same setup I was also going to run plus cams and other upgraded internals in the heads. Those hp and torque numbers look pretty good, I'd love to squeeze out 400 HP though

[Wayne Presley]

It's getting cams and springs Friday so it should crest 400 RWHP by the weekend.

[coloskydiver]

Are these kit in stock and ready to ship?

[Hindsight]

Wayne, very interested in hearing if the cams cause spool-up faster/lower in the RPM band. I have read that some cams on the market will do this and still increase upper RPM power as well so very curious to see if it is true (if you are going with a set of cams that are geared for this).

[STiPWRD]

It's getting cams and springs Friday so it should crest 400 RWHP by the weekend.
Awesome! that would be very encouraging. Any other details? I'll be running the Crower 264 cams and springs. I'm assuming your tuning with the Electromotive ECU?

[Wayne Presley]

Are these kit in stock and ready to ship?
Yes they are, I have mounts for the 02-04 and 05-07 WRX donors


Wayne, very interested in hearing if the cams cause spool-up faster/lower in the RPM band. I have read that some cams on the market will do this and still increase upper RPM power as well so very curious to see if it is true (if you are going with a set of cams that are geared for this).
Well we'll get to see back to back comparisons end of this week or beginning of next.


Awesome! that would be very encouraging. Any other details? I'll be running the Crower 264 cams and springs. I'm assuming your tuning with the Electromotive ECU?

They are the Brian Crower stage 2 cams with 272 duration and tuned with the Electromotive ECU. The ECU is controlling the fuel, spark, fans, fuel pump, AWIC pump, and boost control solenoid.

[metros]

Hopping over here from metalmakers thread as to not throw his off topic. When does the VCP water reservoir option come out for your a2wic?

I would think having a reservoir that you can throw ice packs into between sessions would help to cool the water system back down before heading out on track again. Plus the additional fluid volume would help keep the water cooler, longer on track.

[Wayne Presley]

I can add the reservoir to the system now. Would you like the 2.5 gallon or the 4 gallon?

[metros]

I have already purchase the AWIC, but would be interested in the reservoir when I'm a little further in my build.

For planning purposes, what's the size comparison between the two?

[Wayne Presley]

Well I got it on the dyno with the cams installed and it made 410 RWHP and 397 RWTQ

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818Gill_zps32170d1d.png (http://s213.photobucket.com/user/vcpinjectionpb/media/818Gill_zps32170d1d.png.html)

Here's the datalog of the pull showing the manifold air temp

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/AWICdatalog_zps6603ac0d.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/AWICdatalog_zps6603ac0d.jpg.html)

[metalmaker12]

Nice!!!!

[Hindsight]

Wow, look at that flat line! Nice.

[Wayne Presley]

And that air temp is after a full warm up and 10 pulls...

[Hindsight]

Nice, was this on your 6cyl 818 or a customer's 4cyl that has the AWIC kit on it?

[Wayne Presley]

My AWIC on a customer car with a hybrid 2.5 with 2.0 heads, BC cams, valve springs with Ti retainers, Bloch 2.5 XT turbo, 1000 cc injectors.

[JeromeS13]

Wayne,

Any idea of the air temp at the compressor outlet, pre-intercooler?

Thanks!

[Wayne Presley]

It was 89F and inlet temp is 98 so 9°F above ambient is pretty good with no high speed air flow. I did not log pre IC air temps but I'd figure at least 180°F.

[JeromeS13]

Maybe I'm just outside of my turbo's efficiency range? I was getting pre IC temps of ~ 279 degress F... :-/

[Wayne Presley]

279°F, holy crap that's hot!

[JeromeS13]

279°F, holy crap that's hot!

That's what I'm coming to realize. That's only ~18 psi coming from an IHI VF37 turbo (JDM STI turbo). It was originally designed for the 2.0L. Maybe that's where my problem is... I think the next thing on my shopping list is the Blouch 1.5 XT-R. If I maintain the same power ratings, I should be able to cool that charge temperature by a pretty good bit.

[D Clary]

34265I bought some aluminum tubing to run parallel to the cooling tubes, takes a little less room and weighs less than 8 ft of hose

[metalmaker12]

34265I bought some aluminum tubing to run parallel to the cooling tubes, takes a little less room and weighs less than 8 ft of hose

Where did you get tubeing, I have a similar use for it.

[Hindsight]

Wayne, on that dyno run you mention, did you have the radiator fans running, and did you use any foam or anything to seal between the heat exchanger and radiator?

Thanks

[Wayne Presley]

Radiator fans were running and no foam between the radiator and HE. The fans were able to pull a sheet of paper from 6" in front of the HE when dropped so I'd say the fans are pulling a significant amount of air through it even sitting still.

[metros]

Those are stock or aftermarket fans?

[Hindsight]

Nice! All this time I have been concerned with elaborate methods of ducts and baffles to force the air through and seal the rad to the HE. Great to know it is not needed and is just plug and play!

[Wayne Presley]

Stock fans and you could improve the flow by just using foam between the HE and radiator.

[Wayne Presley]

First post was edited to add the bleeder.

[Frank818]

First post was edited to add the bleeder.

Interesting, it doesn't say it has been edited with the small italic line at the end of the post. I guess it's cuz you are an Admin, god you have a lot of power! :) And that you are such a nice guy, even to this well dressed, smart and fun Canadian :cool:

[Wayne Presley]

It's good to be an admin.

[STiPWRD]

Wayne, thanks for posting the dyno plots. Looks like you're hitting full boost 21 psi around 4300 RPM - am I being too conservative or is the AFR a bit lean? Did you start rich and then go lean? Any comments on the timing? Either way those HP and torque numbers look great and I'll try to replicate for that AFR curve since I'm going to be running a very similar setup.

[GUNS]

Wayne, what did you use as a power source for the pump? I'm assuming you would want this thing running constantly or do you have it hooked up to a switch?

[Wayne Presley]

Wayne, thanks for posting the dyno plots. Looks like you're hitting full boost 21 psi around 4300 RPM - am I being too conservative or is the AFR a bit lean? Did you start rich and then go lean? Any comments on the timing? Either way those HP and torque numbers look great and I'll try to replicate for that AFR curve since I'm going to be running a very similar setup.

That AFR is with 110 octane gas and it's only 12.1 when the boost is ramping in and 11.8 or lower for the rest of the pull. With pump gas and the 10% ethanol in the mix, you will want to run it around 11.3-11.4 AFR. The timing curve was set by running it on the dyno and seeing what the motor liked until it stopped picking up torque.


Wayne, what did you use as a power source for the pump? I'm assuming you would want this thing running constantly or do you have it hooked up to a switch?

I use a fused relay hooked up to the fuel injector power source so you have the pump run anytime the engine is on. You could put an over ride switch to run the pump with the car off.

[metros]

Bumping this thread with a few questions.

I found this fitting next to the drain valve. Is this intended for a temp sensor? Would that be a good location for one? My thought is this is probably on the cooler side of the entire system as it's on the front side of the heat exchanger. Thread pitch?
http://i100.photobucket.com/albums/m35/mxmetros6/818%20Build%20Album/20141219_102611_zpsmeepxr5e.jpg

If I wanted to purchase 90* brass fittings for the large heat exchanger ports, what size fitting should I be looking at?

These fittings:
http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818-build%201/P1020903_zps78fe1e30.jpg

[Wayne Presley]

Bumping this thread with a few questions.

I found this fitting next to the drain valve. Is this intended for a temp sensor? Would that be a good location for one? My thought is this is probably on the cooler side of the entire system as it's on the front side of the heat exchanger. Thread pitch?
http://i100.photobucket.com/albums/m35/mxmetros6/818%20Build%20Album/20141219_102611_zpsmeepxr5e.jpg

If I wanted to purchase 90* brass fittings for the large heat exchanger ports, what size fitting should I be looking at?

These fittings:
http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818-build%201/P1020903_zps78fe1e30.jpg

That would be the place for the water temp sender for the system as that is the feed temp for the pump/core. I'll send you one or if you are in a hurry you can pick up a 1/2NPT street elbow from your local hardware store. Let me know which you want to do. You are the second person I've seen using two 90° on the HE so I'll make that standard on the kits from now on.

[metros]

Thanks for the quick reply. I'm headed to the hardware store today anyways so no worries there.

[K3LAG]

I used a 2nd 90 as well. I got it from Grainger. No luck at Home Depot or Lowes.

Larry

[C.Plavan]

I had to extend my top port with a 3" extender and a 90 degree to keep the hose from kinking.
http://i.imgur.com/PHbebAOl.jpg

[metalmaker12]

Same here

[metros]

Hey Wayne,
I'm finally getting to mounting the actual AWIC. I'm looking at the pictures you've posted at the beginning and double checking I am picturing everything correctly.

I'm using the turbosmart plumb back option.

It looks like the parts I have are similar to the below picture. Only instead of the BOV mount it's just a plain aluminum tube.
http://i213.photobucket.com/albums/cc175/vcpinjectionpb/P1020653_zps85b39c28.jpg

I do not have a piece to couple the 2 - 90* elbows together going into the AWIC core. I'm assuming that's just a 2.5" aluminum tube that I can procure locally.

What do these side tab/mounts connect to in the chassis? Do they use the stock IC mounting brackets?
http://i213.photobucket.com/albums/cc175/vcpinjectionpb/P1020710_zps3d1bc947.jpg

Next question:
For those of us with the heater tubes that are spread farther apart - the 45* elbow coming out of the turbo is hitting the heater hardline. I've got it pushed onto the turbo outlet as far as it will allow. Next step is trimming down one side of the silicone to allow clearing the heater hardline.
http://i100.photobucket.com/albums/m35/mxmetros6/818%20Build%20Album/20150410_152003_zpshenhoczo.jpg

[STiPWRD]

Jason, I have an extra upper coolant cross-over pipe that gives you that much shorter heater loop. You'd have to remove your intake manifold to install it but it'll give you more room near your turbo outlet. Text me if you want it.

[Wayne Presley]

Metros. PM me your email address and I'll send the updated instructions

[metros]

Jason, I have an extra upper coolant cross-over pipe that gives you that much shorter heater loop. You'd have to remove your intake manifold to install it but it'll give you more room near your turbo outlet. Text me if you want it.

Going to try to make this work instead of removing my intake manifold. After trimming the 45* hose down it clears ok now and should work. I appreciate the offer though.


Metros. PM me your email address and I'll send the updated instructions

PM'd

[C.Plavan]

You guys may want to check for leaks on the black wing nut. There is a rubber o-ring on it. My O-ring was split in two and leaking. I swapped it out with spares I had.

http://i100.photobucket.com/albums/m35/mxmetros6/818%20Build%20Album/20141219_102611_zpsmeepxr5e.jpg

[Mechie3]

Frank had similar issues. I believe it's because it's a face seal but the o-ring isn't captured so when it's compressed it never bottoms out. Keep cranking and the o-ring just keeps compressing until it splits. Just be careful with how tight you make it and I'd recommend some backup sealant. It's not a VCP issue, they're all like that.

[Wayne Presley]

I have been checking the O rings lately. The plug is packaged on the side of the HE and I had a customer that swore it wasn't there so I pull them out and put the plug in the hardware bags. He eventually found it on the floor. I found 2 split since doing that so all get checked and replaced if needed.

[metros]

Thanks for the updated instructions. That makes the picture much clearer.

One last question. Are you using the stock rubber hose for plumbing the turbosmart bpv back into the intake?

[Wayne Presley]

Yes you do

[bompus]

I bought my own air bleeder valve, since I purchased the AWIC before it was offered as an option. Do you have any tips on where to install it ( highest point either side of IC? ) , and how to get all of the metal shavings out after I am done?

[tmoretta]

Can the AWIC system be installed without removing the already installed side sails on a completed car? Can the heat exchanger/radiator be installed in the rear, or hoses in the cockpit?

[Mechie3]

I ran my coolant lines down through the center console to keep them away from the hot coolant lines.

[tmoretta]

I doubt I still have room in there - what with the mega wiring bundles.

[Mechie3]

I have the iWire harness so plenty of room. I also cut off the top of the tunnel aluminum and riveted the sides in place. Top piece will be bolt on so it can be removed for maintenance/access.

[508wrx]

Can the AWIC system be installed without removing the already installed side sails on a completed car?

Yes. I installed mine without removing the side sails. Thought It would have been much easier to do it with them off.

[Buzz Skyline]

Yes. I installed mine without removing the side sails. Thought It would have been much easier to do it with them off.

I couldn't figure out a way to run the hoses without removing the side sails. I guess you could thread them through if you're persistent enough and run one hose on each side, but I decided to run the supply and return together on the side with the cool radiator pipe. So I only had to remove the driver's side sail.

[Wayne Presley]

Can the AWIC system be installed without removing the already installed side sails on a completed car? Can the heat exchanger/radiator be installed in the rear, or hoses in the cockpit?
Yes you can, feed the hoses from the front and they will slide right down. I pulled the hose once I could reach it. Run the pump output down the driver side so you keep cool hose next to cool hose. The rest is easy.


I couldn't figure out a way to run the hoses without removing the side sails. I guess you could thread them through if you're persistent enough and run one hose on each side, but I decided to run the supply and return together on the side with the cool radiator pipe. So I only had to remove the driver's side sail.

Or you can do that. It's easier to do on the car as you build it but on a complete car isn't bad.

[tmoretta]

Is there latitude as to where to mount the pump? My ABS pump is just to rear of battery. Also, I have only seen pics. of the front mounted hardware without body panels, I am assuming everything fits fine in front of the radiator and between the mounted fiberglass body panels? Also in the rear- good clearance with shock tower support, engine cover etc.?

[Wayne Presley]

The pump can be mounted in a few different places BUT it has to be mounted low as the pump is a centrifugal and will not suck up high. The IC core has clearance around the mounts and panels. I mounted the pump on this last car forward and worked out well.

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/818-build%201/20160420_164114_zpse98fdxfn.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/818-build%201/20160420_164114_zpse98fdxfn.jpg.html)

[tmoretta]

Is there a preferred location to drill and tap in a sensor for intercooled air temp? Also, how many amps does the pump draw? What is the difference between a BPV and BOV? My engine is mostly stock '02 WRX (VF 39 turbo, Crower street cams, Cobb turbo controller, mild tune) with stock AAIC and valve.

[STiPWRD]

Is there a preferred location to drill and tap in a sensor for intercooled air temp? Also, how many amps does the pump draw? What is the difference between a BPV and BOV? My engine is mostly stock '02 WRX (VF 39 turbo, Crower street cams, Cobb turbo controller, mild tune) with stock AAIC and valve.
1. Measure air temp anywhere between the intercooler and throttle body. Some drill and tap at the bottom of their AWIC where the air collects to go into the throttle body.
2. The Bosch pump that most are using (P/N 0392022002) will draw just under 4 amps.
3. BPV (by-pass valve) recirculates the pressurized air back into the turbo inlet pipe when you let off throttle and is more discrete/quiet. BOV (blow-off valve) releases the pressurized air to atmosphere when you let off the throttle and makes a pshhhhhhhhh sound. A slight rich condition occurs with the BOV since it releases air already measured by the MAF.

[Hindsight]

I tried a bov and even with a stiff spring, it would vent at timed i didnt want it to which caused issues. I would strongly suggest a BPV for a MAF setup.

[tmoretta]

How far back does the intercooler project towards the rear, measured from the throttle body? My trunk mounted spare tire touches against the rear of the intercooler now, and according to pics. I've seen of the air to water intercooler, looks like the new unit projects further back than stock.

[Sgt.Gator]

How far back does the intercooler project towards the rear, measured from the throttle body? My trunk mounted spare tire touches against the rear of the intercooler now, and according to pics. I've seen of the air to water intercooler, looks like the new unit projects further back than stock.

LOL, same question, but because I'm looking at using Wayne's system in a stock STI.