UPDATE: Pic of Paolo Castellano's DIY TT InterCooler

[JGK95]

UPDATE: Pic of Paolo Castellano\'s DIY TT InterCooler

Check out the intercooler for this DIY TT!

Do It Yo-self!!

For those of you who are looking for a LARGE & Efficient Intercooler to go along with the CPE DIY TT... Enjoy!

Is it wide enough?

 

[Viper4Christ]

Re: UPDATE: Pic of Paolo Castellano\'s DIY TT InterCooler

Paolo sure knows what he's doing all right. Man, you could cool down a full scale production power plant with that thing.

 

[Jim Wilson]

Re: UPDATE: Pic of Paolo Castellano\'s DIY TT InterCooler

Do you have any photos with the facia off? I'd like to see how the piping is routed.

 

[Paolo Castellano]

Re: UPDATE: Pic of Paolo Castellano\'s DIY TT InterCooler

Paolo sure knows what he's doing all right. Man, you could cool down a full scale production power plant with that thing.

Chris, That's the idea, right!

 

[Paolo Castellano]

Re: UPDATE: Pic of Paolo Castellano\'s DIY TT InterCooler

Do you have any photos with the facia off? I'd like to see how the piping is routed.

Jim, it's pretty simple, just a 90 in on one side and an out on the other side!
Functionality and simplicity for the bolt-on crowd!

 

[Mark Red GTS Cooper]

Re: UPDATE: Pic of Paolo Castellano\'s DIY TT InterCooler

What about air restriction to the radiator? From the pics it appears there is little to no air flow!

Pics of the tubing routing would be nice also!

Mark

 

[Paolo Castellano]

Re: UPDATE: Pic of Paolo Castellano\'s DIY TT InterCooler

What about air restriction to the radiator? From the pics it appears there is little to no air flow!

Pics of the tubing routing would be nice also!

Mark

Mark, there are several things to consider when sizing an intercooler.


1. You definitely need to flow a certain amount of CFM for a given target HP level.

Without #1, there are several negatives. Firstly, there WILL be a restriction in terms of the overall level of efficiency of the system ie the turbos will have to work harder to move the air through the restriction.

The turbos working harder means a higher shaft/compressor wheel speed which generates more heat into the intake charge that the intercooler has to try to dissipate. This generates a downward spiral of diminishing marginal returns which only gets worse and worse with more and more boost.

I can understand your fear of the intercooler blocking the radiator as I had similar issues with my supercharger on hot days.

The thing you have to realize is that the supercharger is continuously compressing the air as long as the crankshaft is spinning.

Turbos only compress air when they are under load: This is farily significant when considered in the perspective of the big picture.

The intercooler core we are using basically has a core that is completely open in the center allowing a good amount of air to go through it. The end tanks are towards the outside anyway and do not have much frontal surface area compared to the top to bottom end tanks that are 3" tall run 28" across the top AND bottom of the top to bottom intercoolers.

If you have the larger supercharger intercooler from about the same time I had mine, I believe your bottom to top core is about 8" of core from top to bottom with 3" end tanks going 28 inches across the entire width of the radiator opening. Think about it, you have 6" X 28" completely blocking your radiator air inlet. That is 168 square inches of the 408 square inches total from the stock radiator core center section being 17" X 24" wide(408 square inches). 168/408 = almost 42% blockage not to mention the blockage of the good flowing part of the 8" X 28" core portion.

So you combine the supercharger compressing air all the time with the blockage percentage and the wrong climate and I can see why you are worried.

I am thinking that these climates would be better suited to have no intercooler and a water/methanol injection system to quench the heat resulting from the turbos or supercharger compressing the air.

I hope this helps. Please let me know if I can further clarify anything else!

 

[Qualitywires.com]

Re: UPDATE: Pic of Paolo Castellano\'s DIY TT InterCooler

looking good Paolo! What size is the intercooler core? 3"?

Is your core a Spearco design? What Paolo speaks of on the supercharger and turbo putting a load on the engine and heating it up is true....If I am not mistaken, turbos put less stress on the engine at normal driving....when it goes into boost is where you better know what you are doing.

Keep the pics coming! AWESOME!

 

[SVS Turbo]

Re: UPDATE: Pic of Paolo Castellano\'s DIY TT InterCooler

What about air restriction to the radiator? From the pics it appears there is little to no air flow!

Pics of the tubing routing would be nice also!

Mark

Mark, there are several things to consider when sizing an intercooler.


1. You definitely need to flow a certain amount of CFM for a given target HP level.

Great info! So exactly how much cfm does your intercooler flow?

 

[Carleton]

Re: UPDATE: Pic of Paolo Castellano\'s DIY TT InterCooler

Paolo

You have a PM.

 

[J DAWG]

Re: UPDATE: Pic of Paolo Castellano\'s DIY TT InterCooler

Looking good PC. Nice to see the IC option for those with cast pistons who may want to only run a small amount of boost and also good for the forged cars who want to turn the wick up. Glad to see it is a complete package.


John

 

[Paolo Castellano]

Re: UPDATE: Pic of Paolo Castellano\'s DIY TT InterCooler

[quote

Great info! So exactly how much cfm does your intercooler flow?

[/QUOTE]

Jr, to answer your question accurately, you will need to specify several conditions for me:

1. Air inlet temp
2. Pressure ratio
3. Cooling air flow rate set with how many inches of water pressure drop
4. Cooling air temp

You see, you can flow good amount of air through just about any core, whether it is efficient or not is a whole other story.

This core is within 8.5% of the internal volume of the combined core volume from my twin intercoolers with which I made 1278 RWHP and 1509 RWTQ.

Like I said before, the highest air inlet temperatures I experienced after a 116-216 MPH Mustang dyno pull in .69 overdrive was 113 degrees. I would say the capacity of the bolt-on intercooler should be similar for similar conditions.

I would also think that in real world conditions the airflow through 200+ MPH air should lead to even cooler air charge temperatures than the relatively small amount of air pushed through the intercoolers from the fan in front of the car on the dyno.

 

[Paolo Castellano]

Re: UPDATE: Pic of Paolo Castellano\'s DIY TT InterCooler

looking good Paolo! What size is the intercooler core? 3"?

Is your core a Spearco design? What Paolo speaks of on the supercharger and turbo putting a load on the engine and heating it up is true....If I am not mistaken, turbos put less stress on the engine at normal driving....when it goes into boost is where you better know what you are doing.

Keep the pics coming! AWESOME!

Adam, it is a 4" bar and plate core.

You are also correct about turbos stressing the engine less under normal/low load driving conditions!

I am glad you like the pictures! I will keep you posted!

 

[Paolo Castellano]

Re: UPDATE: Pic of Paolo Castellano\'s DIY TT InterCooler

Looking good PC. Nice to see the IC option for those with cast pistons who may want to only run a small amount of boost and also good for the forged cars who want to turn the wick up. Glad to see it is a complete package.


John

John, I am glad you like the pics! I will keep them coming!

 

[TOOOFST]

Re: UPDATE: Pic of Paolo Castellano\'s DIY TT InterCooler

LOOOKING GOOD!
MORE PICS OMOH!

 

[SVS Turbo]

Re: UPDATE: Pic of Paolo Castellano\'s DIY TT InterCooler

[quote

Great info! So exactly how much cfm does your intercooler flow?

Jr, to answer your question accurately, you will need to specify several conditions for me:

1. Air inlet temp
2. Pressure ratio
3. Cooling air flow rate set with how many inches of water pressure drop
4. Cooling air temp

You see, you can flow good amount of air through just about any core, whether it is efficient or not is a whole other story.

This core is within 8.5% of the internal volume of the combined core volume from my twin intercoolers with which I made 1278 RWHP and 1509 RWTQ.

Like I said before, the highest air inlet temperatures I experienced after a 116-216 MPH Mustang dyno pull in .69 overdrive was 113 degrees. I would say the capacity of the bolt-on intercooler should be similar for similar conditions.

I would also think that in real world conditions the airflow through 200+ MPH air should lead to even cooler air charge temperatures than the relatively small amount of air pushed through the intercoolers from the fan in front of the car on the dyno.




[/QUOTE]

I was just wondering what the rating (cfm) was on the specific core that you chose.

When you buy a core at a certain size and design they all have a cfm rating. I understand that you need to have a certain amount of cfm for a specified amount of horsepower. The cfm in your intercoooler will specify how much power it will handle before you start running out of efficiency?

 

[Paolo Castellano]

Re: UPDATE: Pic of Paolo Castellano\'s DIY TT InterCooler

[quote

Great info! So exactly how much cfm does your intercooler flow?

Jr, to answer your question accurately, you will need to specify several conditions for me:

1. Air inlet temp
2. Pressure ratio
3. Cooling air flow rate set with how many inches of water pressure drop
4. Cooling air temp

You see, you can flow good amount of air through just about any core, whether it is efficient or not is a whole other story.

This core is within 8.5% of the internal volume of the combined core volume from my twin intercoolers with which I made 1278 RWHP and 1509 RWTQ.

Like I said before, the highest air inlet temperatures I experienced after a 116-216 MPH Mustang dyno pull in .69 overdrive was 113 degrees. I would say the capacity of the bolt-on intercooler should be similar for similar conditions.

I would also think that in real world conditions the airflow through 200+ MPH air should lead to even cooler air charge temperatures than the relatively small amount of air pushed through the intercoolers from the fan in front of the car on the dyno.

I was just wondering what the rating (cfm) was on the specific core that you chose.

When you buy a core at a certain size and design they all have a cfm rating. I understand that you need to have a certain amount of cfm for a specified amount of horsepower. The cfm in your intercoooler will specify how much power it will handle before you start running out of efficiency?



[/QUOTE]

Jr, the core should be good to about 1250 RWHP especially running lower boost with the big turbos.

 

[SVS Turbo]

Re: UPDATE: Pic of Paolo Castellano\'s DIY TT InterCooler

[quote

Great info! So exactly how much cfm does your intercooler flow?

Jr, to answer your question accurately, you will need to specify several conditions for me:

1. Air inlet temp
2. Pressure ratio
3. Cooling air flow rate set with how many inches of water pressure drop
4. Cooling air temp

You see, you can flow good amount of air through just about any core, whether it is efficient or not is a whole other story.

This core is within 8.5% of the internal volume of the combined core volume from my twin intercoolers with which I made 1278 RWHP and 1509 RWTQ.

Like I said before, the highest air inlet temperatures I experienced after a 116-216 MPH Mustang dyno pull in .69 overdrive was 113 degrees. I would say the capacity of the bolt-on intercooler should be similar for similar conditions.

I would also think that in real world conditions the airflow through 200+ MPH air should lead to even cooler air charge temperatures than the relatively small amount of air pushed through the intercoolers from the fan in front of the car on the dyno.

I was just wondering what the rating (cfm) was on the specific core that you chose.

When you buy a core at a certain size and design they all have a cfm rating. I understand that you need to have a certain amount of cfm for a specified amount of horsepower. The cfm in your intercoooler will specify how much power it will handle before you start running out of efficiency?

Jr, the core should be good to about 1250 RWHP especially running lower boost with the big turbos.

[/QUOTE]

Awesome! that's alot of power, 1250rwhp

If you take 2 intercooler cores that are the same size in volume and surface area but different in cfm flow design, then you can have one intercooler flowing much greater cfm compared to the other, right? So if your basing size and volume compared from your other set up to this intercoolers size and volume you may not have the efficiency you think you have. It's quite simple and theirs a cfm rating that comes with every intercooler core. I would think that with all the calculations that you know this one would be easy to state the cfm and calculate why it would be a good intercooler for up to 1250rwhp. I Just don't want to see you buying a bunch of intercoolers and then find out they only flow about 700cfm

 

[Paolo Castellano]

Re: UPDATE: Pic of Paolo Castellano\'s DIY TT InterCooler

[quote

Great info! So exactly how much cfm does your intercooler flow?

Jr, to answer your question accurately, you will need to specify several conditions for me:

1. Air inlet temp
2. Pressure ratio
3. Cooling air flow rate set with how many inches of water pressure drop
4. Cooling air temp

You see, you can flow good amount of air through just about any core, whether it is efficient or not is a whole other story.

This core is within 8.5% of the internal volume of the combined core volume from my twin intercoolers with which I made 1278 RWHP and 1509 RWTQ.

Like I said before, the highest air inlet temperatures I experienced after a 116-216 MPH Mustang dyno pull in .69 overdrive was 113 degrees. I would say the capacity of the bolt-on intercooler should be similar for similar conditions.

I would also think that in real world conditions the airflow through 200+ MPH air should lead to even cooler air charge temperatures than the relatively small amount of air pushed through the intercoolers from the fan in front of the car on the dyno.

I was just wondering what the rating (cfm) was on the specific core that you chose.

When you buy a core at a certain size and design they all have a cfm rating. I understand that you need to have a certain amount of cfm for a specified amount of horsepower. The cfm in your intercoooler will specify how much power it will handle before you start running out of efficiency?

Jr, the core should be good to about 1250 RWHP especially running lower boost with the big turbos.

Awesome! that's alot of power, 1250rwhp

If you take 2 intercooler cores that are the same size in volume and surface area but different in cfm flow design, then you can have one intercooler flowing much greater cfm compared to the other, right? So if your basing size and volume compared from your other set up to this intercoolers size and volume you may not have the efficiency you think you have. It's quite simple and theirs a cfm rating that comes with every intercooler core. I would think that with all the calculations that you know this one would be easy to state the cfm and calculate why it would be a good intercooler for up to 1250rwhp. I Just don't want to see you buying a bunch of intercoolers and then find out they only flow about 700cfm

[/QUOTE]

Jr, I know there is less pressure drop with the two individual cores as compared to one big one.

I think we have to test the intercooler on one of my big power systems with big turbos to see what the air inlet temperatures are on the dyno and on the street.

The overall efficiency of the system ie getting the cool air into the turbos, through efficient intercooler plumbing and then of course a monster exhaust with a properly designed wastegate will do wonders to how hard the turbos will have to work to move a given amount of air.

I appreciate your concern for Viper brother trying to help me size the intercooler, but like I have said already, the proof will be in the pudding when we get one of these on somebody's car who wants to make some big power. There are several guys interested in such a system. We have done everything to engineer this system to accomodate a pair of 76 GTS turbos with large exhaust housings all the way down to the baby 590 HP each turbos that come on the base systems! Good luck making big power yourself!

 

[Viper4Christ]

Re: UPDATE: Pic of Paolo Castellano\'s DIY TT InterCooler

Quote:
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Paolo sure knows what he's doing all right. Man, you could cool down a full scale production power plant with that thing.


--------------------------------------------------------------------------------



Chris, That's the idea, right!

Thats the idea alright, the cooler it is the better it works. And all I can say to anyone else that might doubt Paolo... talk to him yourself it's simply basic real world results and explanitions no BS needed

 

[00SVTdubs]

Re: UPDATE: Pic of Paolo Castellano\'s DIY TT InterCooler

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