Hello! Log in or Register   |  Help  |  Donate  |  Buy Shirts  See all banner ads | Advertise on TheSamba.com  
TheSamba.com
 
Air to air intercooler in D pillar ideas please!
Page: Previous  1, 2, 3, 4, 5, 6  Next
Forum Index -> Vanagon Share: Facebook Twitter
Reply to topic
Print View
Quick sort: Show newest posts on top | Show oldest posts on top View previous topic :: View next topic  
Author Message
Gizmoman
Samba Member


Joined: September 10, 2011
Posts: 1303
Location: San Diego
Gizmoman is offline 

PostPosted: Mon Dec 22, 2014 6:21 pm    Post subject: Reply with quote

Obviously this is one of those" best for you is best". Everyone has different opinions and needs and if the outcome brings satisfaction, then it's all good.

My biggest reason for tossing in the photos was to add to the variables. If a person is willing to fab a new intake (not as tough as it seems), very short charge piping is doable. If an air to air unit is your preference, it can be put in the same place as the WAIC I posted.

I originally had a much smaller radiator and fan. It was noisy and not nearly as efficient as the much larger unit I have now. Besides, it makes no noise at all.
_________________
82 Vanagon Westy - AAZ 1.9 TD, HE200 Holset, WAIC, 27.75 dia tires, Electric power steering, 5-speed AAP w/.078 5th

Oversize Spare rack - stock location https://www.thesamba.com/vw/classifieds/detail.php?id=2169071
Back to top
View user's profile Send private message Send e-mail Gallery Classifieds Feedback
MarkWard
Samba Member


Joined: February 09, 2005
Posts: 10364
Location: Riviera Beach, Florida
MarkWard is offline 

PostPosted: Mon Dec 22, 2014 1:00 pm    Post subject: Reply with quote

Gizmoman, that is some pretty custom stuff you have there.
_________________
1982 Vanagon Camper with ALH TDI conversion.
1990 Vanagon Camper Syncro conversion.
Back to top
View user's profile Send private message Gallery Classifieds Feedback
lloydy
Samba Member


Joined: September 15, 2010
Posts: 694
Location: cheam surrey
lloydy is offline 

PostPosted: Mon Dec 22, 2014 12:05 pm    Post subject: Reply with quote

I'll agree with you and say the charge cooler is overall better, in that the average temps are slightly lower. But, the intercooler on mine is more than adequate. I know its now winter... but my IAT's are on average 35degc, summer was about 10c higher. Totally fine for the engine, way within any parameters.
_________________
16" multivan pop top AFN TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.”
Back to top
View user's profile Send private message Classifieds Feedback
Gizmoman
Samba Member


Joined: September 10, 2011
Posts: 1303
Location: San Diego
Gizmoman is offline 

PostPosted: Mon Dec 22, 2014 8:27 am    Post subject: Reply with quote

I appreciate the simplicity of an air to air unit but the efficiency of water to air is hard to beat. I installed a huge cooler and have no fan at all. My temps are 10 degrees over ambient most of the time. There is a small plastic tank under the back seat (cheap washer fluid reservoir) which I use to easily fill the system and I have a bleeder valve inserted in the highest spot in the plumbing.

I also feel that the power plant in our vans is nearly always getting pushed to it's limits so the comment about drag racing may actually be more appropriate than you may think. A lot of non van mechanics/drivers don't realize the severity of the application, but if you relate your van to most other cars you own, the van gets worked much harder.

Here is my set-up

Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.
[/img]
_________________
82 Vanagon Westy - AAZ 1.9 TD, HE200 Holset, WAIC, 27.75 dia tires, Electric power steering, 5-speed AAP w/.078 5th

Oversize Spare rack - stock location https://www.thesamba.com/vw/classifieds/detail.php?id=2169071
Back to top
View user's profile Send private message Send e-mail Gallery Classifieds Feedback
dkoesyncro
Samba Member


Joined: December 10, 2006
Posts: 716

dkoesyncro is offline 

PostPosted: Sun Dec 21, 2014 6:39 pm    Post subject: up from the dead Reply with quote

The talk and thought of intercoolers has been on my mind alot lately! My latest thought has been to tuck a renault intercooler up into the d pillar. http://www.forgemotorsport.co.uk/userfiles/images/...cooler.jpg a
I thought louvering the d pillar similar to the splitties and putting a puller fan on would produce good intake temps.

The saab looks to be a good fit for those who have the outlet/inlets on the same side. I have the opposite thing happening here http://www.thesamba.com/vw/forum/album_page.php?pic_id=1229550

you see the turbo far left and TB far right. I have a fmic that I was going to put behind the bumper and this would allow less than 2ft of pipe. My thoughts w/ this is heat soak from it being close to exhaust piping and the fact that its the back of the van; no airflow! Even a fan would just be pushing or pulling hot stale air giving its location.

I am hell bent to stay w/ an air to air intercooler once given the complexities of how to make it work i wont have to worry about component failures as a water to air intercooler.

thanks for any help!
Back to top
View user's profile Send private message Gallery Classifieds Feedback
goffoz
Samba Member


Joined: May 09, 2007
Posts: 1486

goffoz is offline 

PostPosted: Sun Aug 17, 2014 11:19 am    Post subject: Reply with quote

Waldi wrote:

But there is one thing to think about. If u drive offroad with trees around, they break easy. Sure also yours. I thought about a round metal in front of the shape clewed to the body.

No problems so far, it protrudes less than the mirrors folded.
The scoop is formed from 0.9mm. thick Aluminum, there is a internal support structure that deflects air down the pillar...very ridgid
The version I'm making now is anchored to the body thru the stock vent mounting points..no drilling required Very Happy
Back to top
View user's profile Send private message Gallery Classifieds Feedback
Waldi
Samba Member


Joined: February 28, 2014
Posts: 1681
Location: Germany
Waldi is offline 

PostPosted: Sun Aug 17, 2014 9:42 am    Post subject: Reply with quote

goffoz wrote:
Here you go, small production run has begun, still dialing in the folding dies

lloydy wrote:
I love that version posted above and would like to see it from a angle that shows how far out the scoop sticks out. I have my name down with a german company, who make one in plastic, but they are sold out at the moment.

[img]
Image may have been reduced in size. Click image to view fullscreen.
[/img]
[img]
Image may have been reduced in size. Click image to view fullscreen.
[/img]


Looks good !
And it looks like bigger airinlet than the plastic ones.
Sure the price is higher than the 50€ (left and right) for the plastik ones and the mounting takes more time.
But there is one thing to think about. If u drive offroad with trees around, they break easy. Sure also yours. I thought about a round metal in front of the shape clewed to the body.
Back to top
View user's profile Send private message Gallery Classifieds Feedback
goffoz
Samba Member


Joined: May 09, 2007
Posts: 1486

goffoz is offline 

PostPosted: Sun Aug 17, 2014 8:33 am    Post subject: Reply with quote

Here you go, small production run has begun, still dialing in the folding dies

lloydy wrote:
I love that version posted above and would like to see it from a angle that shows how far out the scoop sticks out. I have my name down with a german company, who make one in plastic, but they are sold out at the moment.

[img]
Image may have been reduced in size. Click image to view fullscreen.
[/img]
[img]
Image may have been reduced in size. Click image to view fullscreen.
[/img]
Back to top
View user's profile Send private message Gallery Classifieds Feedback
Waldi
Samba Member


Joined: February 28, 2014
Posts: 1681
Location: Germany
Waldi is offline 

PostPosted: Sun Aug 17, 2014 3:21 am    Post subject: Reply with quote

lloydy wrote:
Lucky man! Now, do you actually have four vans?..
He did say he was waiting on a order, then he'll remake. Did you notice a difference before/after with the scoops fitted?


I have 3 syncros, 2 vans and 1 singlecab.
https://fotos.web.de/ui/external/4n1plYojQRe4E6P3rJtBQQ96203
But there are around 10 vans in Italy waiting for the scoobs.
I have ordered 50, and have postet the web from Markus here in the forum with the intension to help him to start the new produktion.

I drive the scoobs since i have my intercooler, around 7 years. And yes they help to cool the engine, even without intercooler they blow the hot air out of the engine room.
Back to top
View user's profile Send private message Gallery Classifieds Feedback
lloydy
Samba Member


Joined: September 15, 2010
Posts: 694
Location: cheam surrey
lloydy is offline 

PostPosted: Sun Aug 17, 2014 2:58 am    Post subject: Reply with quote

Lucky man! Now, do you actually have four vans?..
He did say he was waiting on a order, then he'll remake. Did you notice a difference before/after with the scoops fitted?
_________________
16" multivan pop top AFN TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.”
Back to top
View user's profile Send private message Classifieds Feedback
Waldi
Samba Member


Joined: February 28, 2014
Posts: 1681
Location: Germany
Waldi is offline 

PostPosted: Sun Aug 17, 2014 2:26 am    Post subject: Reply with quote

lloydy wrote:

...
I have my name down with a german company, who make one in plastic, but they are sold out at the moment.


Yeah i got the last 4 sets. But Markus told me he start a new production.
Back to top
View user's profile Send private message Gallery Classifieds Feedback
lloydy
Samba Member


Joined: September 15, 2010
Posts: 694
Location: cheam surrey
lloydy is offline 

PostPosted: Sun Aug 17, 2014 2:14 am    Post subject: Reply with quote

Well, i've now done around 2000 miles with the air/air intercooler. Here is some pics of it fitted
Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.

Vented out underneath
Image may have been reduced in size. Click image to view fullscreen.

It works pretty well, slightly warmer than the water/air set up but no much. Around town @ 30mph-ish inlet temps are around the high 30's (degC) At 50-55mph on long sweeping up and down roads temps read about 45degC . Temps are the same give or take on the motorway at 60-65mph, but can go into the low 50's. Long hills on full boost fully laden it will creep to around 61DegC (highest i noted was 63)
I am happy with that, the peak temps are about the same as the water set up. I do think there is some to be gained by fitting scoop to the top of the D piller. I love that version posted above and would like to see it from a angle that shows how far out the scoop sticks out. I have my name down with a german company, who make one in plastic, but they are sold out at the moment.
_________________
16" multivan pop top AFN TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.”
Back to top
View user's profile Send private message Classifieds Feedback
goffoz
Samba Member


Joined: May 09, 2007
Posts: 1486

goffoz is offline 

PostPosted: Wed Mar 26, 2014 7:07 pm    Post subject: Reply with quote

danfromsyr wrote:
quite a nice and clean install,
but a question what Fan thermostat switch are you using and what temperature would you want to set it at to come on?

I've been eyeing this reasonable one from Summit's fleabay store for under $30shipped
http://www.ebay.com/itm/Hayden-Fan-Switch-Thermost...mp;vxp=mtr
As of right now, its "fan always on"...thats how stephan wired it Confused
From past experience with peculiarities in his wiring...I will have to check with him before installing a switch..it may upset the ECU
As to temps, stephan installs a 180F T stat. and my engine temps are usually 188F to 193F rolling around or cruising on the freeway.
But I live in the Sierras and running up 3000ft on the highway I could see 210Fon the gauge
...since getting the IC all sealed and scooped I haven't crossed 200F yet Very Happy
Back to top
View user's profile Send private message Gallery Classifieds Feedback
bluefirefly
Samba Member


Joined: March 16, 2011
Posts: 438
Location: Calgary, Ab
bluefirefly is offline 

PostPosted: Wed Mar 26, 2014 11:47 am    Post subject: Reply with quote

My fan is controled with the alternator blue wire, always on when the engine is running....
_________________
86 Syncro Tintop G60
work in progress ...as always!
Back to top
View user's profile Send private message Send e-mail Gallery Classifieds Feedback
davevickery
Samba Member


Joined: July 16, 2005
Posts: 2867
Location: Fort Collins, CO
davevickery is offline 

PostPosted: Wed Mar 26, 2014 11:34 am    Post subject: Reply with quote

Could you just attach a normal limit switch to the case of the intercooler. I did that for a hot water tank. Just siliconed it to a place that had good conductivity of the water temp. Only cost a few bucks.
Something like this. http://www.alliedelec.com/search/productdetail.asp...MgodKHUAgw
Back to top
View user's profile Send private message Gallery Classifieds Feedback
lloydy
Samba Member


Joined: September 15, 2010
Posts: 694
Location: cheam surrey
lloydy is offline 

PostPosted: Wed Mar 26, 2014 10:15 am    Post subject: Reply with quote

I got this one, and I'm going to set it up so it switches the fan on when IAT are 50c

http://www.carbuildersolutions.com/uk/adjustable-fan-controller-thermostat
_________________
16" multivan pop top AFN TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.”
Back to top
View user's profile Send private message Classifieds Feedback
danfromsyr
Samba Member


Joined: March 01, 2004
Posts: 11431
Location: Syracuse, NY
danfromsyr is offline 

PostPosted: Wed Mar 26, 2014 9:30 am    Post subject: Reply with quote

quite a nice and clean install,
but a question what Fan thermostat switch are you using and what temperature would you want to set it at to come on?

I've been eyeing this reasonable one from Summit's fleabay store for under $30shipped
http://www.ebay.com/itm/Hayden-Fan-Switch-Thermost...mp;vxp=mtr
_________________
Vanagon List Archives
The only cheap thing in a classic VW sits behind the steering wheel
THE List ala Sanchius
syncroserge wrote:
The way these vans have shaped and enriched our family life would make one believe these darn things have a soul Cool
Back to top
View user's profile Send private message Visit poster's website Gallery Classifieds Feedback
Colorado Yeti
Samba Member


Joined: August 25, 2013
Posts: 306
Location: Ft. Collins, Colorado
Colorado Yeti is offline 

PostPosted: Wed Mar 26, 2014 9:15 am    Post subject: Reply with quote

Goffoz.........thanks for posting this!!
Back to top
View user's profile Send private message Gallery Classifieds Feedback
goffoz
Samba Member


Joined: May 09, 2007
Posts: 1486

goffoz is offline 

PostPosted: Sat Mar 15, 2014 10:44 am    Post subject: Reply with quote

As requested..a pattern for the scoop.
All folds are in the same direction, long diagonal fold could be a gentle curve
notches on the bottom edge, are to clear the vent mounting tabs..a 1/4 " lip along here could suffice.
This pattern works for either side of the van.
Make a templete first, you may need to finese it a bit. Very Happy
Image may have been reduced in size. Click image to view fullscreen.
Back to top
View user's profile Send private message Gallery Classifieds Feedback
goffoz
Samba Member


Joined: May 09, 2007
Posts: 1486

goffoz is offline 

PostPosted: Mon Mar 10, 2014 9:01 pm    Post subject: Reply with quote

Remember this little scoop,
Image may have been reduced in size. Click image to view fullscreen.


Here are the splash shields, and tin around the fan.

Image may have been reduced in size. Click image to view fullscreen.


Here's a view from the under side..this is what is behind the tin (tin is on the left)
The fan bracket is 1/8" steel and supports the IC (intercooler)
I used the D pillar pins and the stock power steering hose mounts to bolt up too...no extra holes Very Happy
...looking rearward from the axle

Image may have been reduced in size. Click image to view fullscreen.


And topside.position is good very solid ,lots of airflow Very Happy

Image may have been reduced in size. Click image to view fullscreen.


Still want to add a cover over the cooler to seal it too the D pillar.
...maybe vac formed plexi Very Happy
I closed off the pillar behind the taillights
Image may have been reduced in size. Click image to view fullscreen.

Here's aview thru the tailight opening
So 100% of the flow goes over the IC..but a litttle scoop on top of the IC would direct more air thru the IC at speed ..and protect the cooler from damage from careless tool use
Back to top
View user's profile Send private message Gallery Classifieds Feedback
Display posts from previous:   
Reply to topic    Forum Index -> Vanagon All times are Mountain Standard Time/Pacific Daylight Savings Time
Page: Previous  1, 2, 3, 4, 5, 6  Next
Page 3 of 6

 
Jump to:  
You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum

About | Help! | Advertise | Donate | Premium Membership | Privacy/Terms of Use | Contact Us | Site Map
Copyright © 1996-2018, Everett Barnes. All Rights Reserved.
Not affiliated with or sponsored by Volkswagen of America | Forum powered by phpBB