Hey Folks,
I have had one or two mildly abusive emails from people complaining that I don’t update this blog enough. The jist of it is that i need to get off my newly married, KFC chomping backside and actually do some work on the cars. So with that fresh in my mind, i gave the workshop a bloody good tidy up and cracked on with this part of the project.
What the f**k is holding you up, you ask? Well – nothing really, it’s mainly time. But now the wedding is out-of-the-way things should progress a bit quicker.
In the time-honoured tradition of the BBC’s Fast Show: “This week i have been mainly working on intercoolers”
The Intercooler:

Intercoolers are important bits of kit on drift cars especially as they function as a bloody great big heat exchanger for your inlet charge. (the air that goes into your engine) On a normally aspirated (N/A) car, the air is sucked in through an air filter and straight into your engine. So providing you keep your underbonnet temperatures low and feed it with nice cool air from a vent etc, you’ll be fine.
A turbo car however, is a very different kettle of fish. The turbo acts as a bit fat air pump pushing air into the engine but because it’s powered by the exhaust gasses the turbo get’s mighty hot. This in turn also heats up the air that’s pushed through the turbo, into the engine.
An intercooler (or specifically an air to air intercooler) acts to cool that air. As the charge passes through the inside of the intercooler, it’s heat is exchanged with the air flowing across the outside of the intercooler – thus reducing it’s temperature and cooling the charge.
Why is cooling the charge so important? Well, basically pre-ignition (what we call det) is caused by the gasses in the cylinder igniting before the piston reaches top dead centre on it’s combustion cycle. This results in the explosion trying to push the piston back down the bore, while the crankshaft and connecting rod are trying to push it up. This is BAD NEWS.
Pre Ignition/Pre Detonation can be caused by a number of things, but one of the main culprit is what we call “auto ignition” To explain auto ignition, you have to understand a principle called adiabatic heating effect. Adiabiatic heating is the effect by which any fluid/gas increases in temperature under pressure/compression. If you think that when a piston is on it’s up cycle, it’s job is to compress the air and fuel into a small space in the combustion chamber where the spark plug then ignites it and that dense packed pocket of gas explodes and expands with great speed and ferocity, pushing your piston down the bore.
When the piston compresses the gas, it dramatically increases in temperature. If the temperature of the air coming in to the engine is too warm, the adiabatic heating effect pushes the temperature of the combustion mix past the auto ignition point of the gasoline (about 280 deg c depending on the octane), causing it to self ignite before the spark plug fires. Ala Det.
On a road car like the S13, you’ll see a natural “seat of the pants” power gain by fitting a Front Mounted Intercooler (FMIC) without doing any other supporting mods. This is because the effect of cooling the air actually makes it more dense. Simply, denser air makes a bigger bang = more power.
Mounting the cooler
There are a couple of possibilities for mounting your intercooler.
Standard Position
I tend to favour the simpler “standard” position you see above. It’s quick, easy and does exactly what you say on the tin (cool the charge) it gives the intercooler loads of cool air flow. It has three disadvantages. 1) It’s hanging off the front of the car, so it’s easier to hit it when drifting. 2) The air that travels through the intercooler into the radiator is warmer than if it was mounted in say, a Vee setup. 3) You use longer intercooler piping which can have an effect on throttle response. However, it’s pretty negligible if im honest.
V-Mount

V-mount setups move the intercooler up into the engine bay and direct the air using ducting. It places the intercooler and the radiator in a V position that allows them to both be fed by cool air at the same time removing the need for one to flow warm air into the other. You also have very short intercooler piping which delivers a nice, crisp throttle response. In addition you are also moving the cooler off the front of the car, which means that it’s less susceptible to damage. There are some significant downsides to this setup however. It’s complexity requires lots of custom ducting and mounts to be fabricated as there are no “off the shelf” kits available for the S13. The other issue is due to the intercooler’s proximity to the engine it’s self, something called “Heat Soak” often occurs which (in layman’s terms) means that the temperature of the intercooler it’s self, becomes more or equal to the air traveling through it. The engine effectively heats up the intercooler and there isn’t enough cool air to reduce its temperature.
While a v-mount setup may look cool, unless your building a straight competition car – Keep It Simple.
How I did mine
There are two main points for mounting your intercooler.
1) Make sure that the bottom of the intercooler is higher than the bottom panel of the chassis. Otherwise, you’ll be smashing it on everything in sight.
2) Make sure that there isn’t anything obstructing the air flow to the intercooler. You’ll see from my picture above that i have cut about 2/3rds of the standard bumper support bar and replaced it with a piece of round bar. While this won’t offer much protection during an impact. It does keep the bar in one piece, support the bumper and adds a little bit of extra strength to the remaining corner pieces.
3) Make it strong. There is nothing worse than somebody who half heartedly bolts on an intercooler that flaps around all the time. You shouldn’t be able to wiggle or move it once it’s on. If there is any movement, it will only result in your boost pipes wiggling loose and falling off without prior notice. If your really unlucky, it’ll cause one of the bloody annoying boost leaks that you can’t find easily and spend the next 8 hours faffing with.
I made up a nice support bar for mine, which i painted up and fitted on the top. There are also two fabbed brackets below to keep it all secure.

Painted

On the car

At the end of the day an intercooler is an intercooler. Don’t go spending thousands on GReddy or HKS branded ones. It’ll just get bent and trashed. XS Power is a crappy ebay brand fo’sho. But it’s made in exactly the same factory as the Autobahn or other UK branded ones (no names mentioned) They all cool air in the same way
Other than intercooler fitting, i fitted a front tow hook (which is almost a necessity when skidding on track)

I also finally got the exhaust back on. I need to make up a couple of extra brackets to make sure it’s all secure, but she’s on. Quick bizzle tip when mating up exhaust surfaces. Don’t use that crappy exhaust paste – it’s brittle and ‘orrible. Get some good quality clear silicone sealer (similar to the stuff you put round your bath tub) it’s what Nasa used to stick on the ceramic tiles to the space shuttle. It’s far better. Put a light smear on either side of your connecting gasket and do it up tight.

More as it happens.
September 13, 2010
Categories: Uncategorized . Tags: auto igntion, det, detonation, exhaust paste, intercooler, pre ignition . Author: mrbizzle . Comments: Leave a Comment