Intercooler relocation & replacement looking for inputs

[RM1SepEx]

I can't live with the TMIC placement and ducting. The ducting and airflow is a joke at best. Wayne has told us about the heat soak issues and why he went to AWIC.

I've checked and with some creative ducting I can move the IC to the right rear side vent, there is plenty of room. I could block off the current BVP and get a BVP adapter. I'd like to avoid the BOV conversion and use the stock BVP.

The stock IC is not well suited due to the Y pipe connection, so I'm looking at alternatives. I can get 30-35% more IC cooling area and flat plate design, with better inlet and outlet orientation. It will also allow dual small fans if needed to help flow the air. I'll be adding an external scoop on the outside of the fender.

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My next quandry is tubing size, since I'm only looking at a stage 2 with my V3 Accessport I'm thinking 2 inch tubing might work best. The IC has 2 1/2 inch inlet and outlet so 2/ 1/2 would also be an option.

I have a short intake, just a silicone connector and the air meter and cone filter. My exhaust is all 3 inch, bellmouth, high flow cat, 90 degree bend, straight through stainless muffler, dump out the bumper

I'm an old fart, no background in turbos, to go faster we added displacement.

Looking for thoughts and inputs, so many have both turbo and Subaru experience

[Frank818]

The guys who did the blue 818 at the White House (TDI 98mpg) located the IC at the very bottom far end of the rear bumper. He said the negative pressure was enough to feed the IC at that location. Maybe that's [an odd] way to go?

[FFR-ADV]

Hi Dan,

I notice that Factory Five is also going with the AWIC on their new track build. It looks like one of the AWICs from FrozenBoost:

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http://thefactoryfiveforum.com/showthread.php?15071-30-Day-818R-Build-Progress-Report

I have had the same concern as you which is why I started the following thread which many contributed links to great outside information:

http://thefactoryfiveforum.com/showthread.php?7680-Hmmm-How-about-a-Air-Water-Intercooler-or-other-aftermarket-options

http://www.iwsti.com/forums/water-meth-injection-nitrous-intercooler-cooling/199117-t-gs-air-water-ic-build.html

Wayne has put together a nice drop in system.

Cheers!

Steve

[C.Plavan]

I bought two 6.5 inch spa fans. That will push the air through I'm hoping. Also keep in mind, the intercoolers on the test cars at the beginning were stock. If one was from a 2006 WRX.... It is the smallest intercooler they made.... I have one. I since have ordered the Mishimoto WRX TMIC which it an improvement over the STI model. I'm hoping the two fans will push enough air through with a little modification of the ducting. If it sucks- Then I will go AWIC.

[RM1SepEx]

I could have slept through my fluids classes in college and still known that the FFR venting isn't good enough.

The TDI application is high mileage vs high HP, I want to be able to do sustained boost... While I do think it could be better than the kit's stock venting, drawing hot engine compartment air won't cut it for most of us. A radiator back there might work as well...

Ducting the air from the side, through an enlarged vent with a "scoop" should provide far more airflow. I just purchased a bar and plate IC with 30% more area and 40% more volume than my stock 05 WRX (approx numbers, misplaced my calcs) That "hip" area of the car is a high pressure area. Some simple ducting and fans if needed should suffice.

I was hoping for more discussion on tubing size vs spool times etc... My turbo "nut" friends (STI, Evo, Miata, et... ) all tell me 2 inch should be fine for 250- 300 whp and my goal is 240-250

[305mouse]

Keep the IC hoses the same diameter as the TB.

[apexanimal]

2.5" is pretty standard typical ic piping for largish hp stuff and might be overkill for what you're looking at...

look to size the pipe up to your ic inlets and outlets with gradual tapers if you need them to get from the turbo and to the tb

[mikeb75]

I've also had concerns about the TMIC being fed enough air in the FFR recommended install location. Something that has always bothered me about tracking my STI was the hoodscoop and adding that much air to the engine bay without an efficient way to get it out without dumping it under the car.

Instead of taking your approach and moving the IC RM1SepEx, I've been looking at using the side inlets to feed ducts that push air from under the IC (in stock location) and will vent the exhaust air out the top of the rear bonnet using a reverse hoodscoop to create a low pressure area directly over the outlet. So I want to reverse the airflow across the IC (from the normal path).

The concerns I have with this approach is will enough air be provided by the side inlets to keep the IC/charge air temps low... may have to do some 'glass work to get more air in and making sure the incoming air is properly channeled to the IC. I figure an aluminum plenum under the IC will serve 2 purposes here: allow ducting of the air properly and give some insulation between the IC and the turbo/block.

I guess diagrams may help... I'll try to put up something so the brain trust here can help out (especially the big brain types with respect to VE and CFD 8) )

[RM1SepEx]

Mike when you look at the actual application, you will see that your approach won't work, no easy way to duct to the stock location. to get there everything is hot in the engine compartment. I'll turbo blanket the turbo and run pipe to the IC like a FMIC

Apexanimal... bigger pipe slower response, more air to move.

Anyone have a source for a BPV adapter for an 05? I don't want to convert to BOV

[apexanimal]

yeah... that's kinda what i was referring to...

has anyone actually done any testing using a magnehelic gauge to test pressure at all the potential openings to see where it will be best to duct/vent from/to?

i have to assume the windshield is going to have an effect on the small shoulder inlets and of course on the engine cover opening... there are a lot of different things to check before working on all the ducting and routing... i think nearly anything will be better than the stock placement, but i'd want to do testing before figuring out what to do...

[RM1SepEx]

The car has pretty wide "hips" the side vents should capture tons of air, with my external scoops...

I might scoop the right side IC vent and cut it back quite a bit, I'll be feeding my intake from there, it sits where the cone filter is on the 30 day FFR 818R, just after the intake's 90 degree bend, over the right cam cover

The left side vent should do nicely for an oil cooler for a "racing" application

[Kurk818]

My plan is to place a FMIC in the rear portion of the car against the bumper and build scoops to channel air into the engine bay compartment. Some form of ducting to channel the air back more efficiently will probably be required.

[RM1SepEx]

That could work....

[metalmaker12]

Awic or top mount with direct flow only in my option

[Frank818]

AWIC all the way for me.

[Kurk818]

the AWIC is an expense i dont want to bare at the moment. The front mount came with my donor so im going to give that a shot and see how it work. Plus, i think the scoops would be bad *** with my wide body and 295's :cool: