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Air to air intercooler in D pillar ideas please!
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lloydy
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PostPosted: Sun Mar 09, 2014 1:28 pm    Post subject: Reply with quote

i did see that thread, some good stuff on there..

here's a shot of roughly how it will be mounted
Image may have been reduced in size. Click image to view fullscreen.

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POS
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PostPosted: Sat Mar 08, 2014 3:26 pm    Post subject: intercooler Reply with quote

"All my life's a circle"

Might take gander at this...

http://www.thesamba.com/vw/forum/viewtopic.php?t=394631&postdays=0&postorder=asc&start=0
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82pdtdi
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PostPosted: Sat Mar 08, 2014 2:59 pm    Post subject: Reply with quote

this is where i am putting my inter cooler still have to duct it in. i plan on adding a 911 turbo type scoop also.
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Waldi
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PostPosted: Sat Mar 08, 2014 12:14 pm    Post subject: Re: my aircooler solution Reply with quote

rmcd wrote:
Waldi wrote:
Hi,
here u can see my solution in a 16 Syncro with AAZ and watercooled turbo.

https://fotos.web.de/ui/external/sI_-gRgXSgiY-kjJIa0RnQ96203

Feel free to insert the pics into ur awnser.


Thanks for the photos Waldy. Very helpful. Your implementation seems to encapsulate the best practices discussed so far.

What function does the piece of bent diamond plate provide? Does this create a low pressure area near the rear inside the fender?

Lloydy. Your craftsmanship makes me tear up. Those bent piece are beautiful. Thanks for posting.


No, its just for dirt protecting. And maybe less overpressure.
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lloydy
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PostPosted: Sat Mar 08, 2014 11:20 am    Post subject: Reply with quote

Now, while i would love to claim this work as my own...... it's not Laughing
All being carried out by the guy doing the bodywork on my van. I'll post pictures for sure as and when work is done, i'm really looking forward to seeing it fitted myself!
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dkoesyncro
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PostPosted: Sat Mar 08, 2014 11:03 am    Post subject: Reply with quote

beautiful job! Please keep us posted. I want to see where this is going to be mounted. Applause
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rmcd
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PostPosted: Sat Mar 08, 2014 10:56 am    Post subject: Re: my aircooler solution Reply with quote

Waldi wrote:
Hi,
here u can see my solution in a 16 Syncro with AAZ and watercooled turbo.

https://fotos.web.de/ui/external/sI_-gRgXSgiY-kjJIa0RnQ96203

Feel free to insert the pics into ur awnser.


Thanks for the photos Waldy. Very helpful. Your implementation seems to encapsulate the best practices discussed so far.

What function does the piece of bent diamond plate provide? Does this create a low pressure area near the rear inside the fender?

Lloydy. Your craftsmanship makes me tear up. Those bent piece are beautiful. Thanks for posting.
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Gizmoman
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PostPosted: Sat Mar 08, 2014 8:12 am    Post subject: Reply with quote

Very nice craftsmanship.
Post your results when you get a chance.

I have a WAIC unit (Frozen Boost)I am just now hooking up. My fan is about the same size as yours but it's cooling water.
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lloydy
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PostPosted: Sat Mar 08, 2014 2:28 am    Post subject: Reply with quote

i thought i would post up a few pics of how my intercooler is shaping up
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internal division to balance cores equally
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better idea here
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mock up
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position of fan sensor
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kit form Laughing
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fast fwd
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used the cad cutter to make the inlet flange mount as its 10mm conical,this is important as a flat plate with a stub would render it likely to flex in and out and over time possibly cause fatigue cracking
Image may have been reduced in size. Click image to view fullscreen.

here the fan mount is welded to the end tanks and the 90' fold is sufficient to prevent movement that could be an issue, also the fan is now securely fixed via SS rivnuts/capheads and is i think a decent way to do this.
Image may have been reduced in size. Click image to view fullscreen.

and so we have this Very Happy
Image may have been reduced in size. Click image to view fullscreen.

so now i will place it and make a simple effective mounting for it
Image may have been reduced in size. Click image to view fullscreen.

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costal_cat
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PostPosted: Sun Mar 02, 2014 4:59 pm    Post subject: Reply with quote

[/quote]
To defeat the pre-heating of the intake air, you could install a water methanol injection system above the charge cooler in the pillar. It would cool the charge cooler, the intake air and keep your EGT down too. Just saying... Smile
Jeff[/quote]

So I was looking at this for my TDI.

http://www.snowperformance.net/mpg-max-vw-tdi.html


Is this what you are thinking?
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Jeff's Old Volks Home
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PostPosted: Sat Mar 01, 2014 2:54 pm    Post subject: Reply with quote

furrylittleotter wrote:
goffoz wrote:
perpetual motion?


Not exactly, but I like where your mind's at. Wink

Here is a flowchart/diagram:

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


The beauty is the higher the rpms, the more flow and the more "precharge" cooling.

Neil2

To defeat the pre-heating of the intake air, you could install a water methanol injection system above the charge cooler in the pillar. It would cool the charge cooler, the intake air and keep your EGT down too. Just saying... Smile
Jeff
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rmcd
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PostPosted: Sat Mar 01, 2014 2:14 pm    Post subject: Reply with quote

Does anybody have pictures of the body modification s necessary to vent to the rear or underneath (is this a low pressure area)?

Would the fan sit on top of the Saab intercooler and pull air into itself and through the intercooler or would it be better to put it under the intercooler? Maybe doesn't matter?
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Howesight
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PostPosted: Fri Feb 28, 2014 12:54 pm    Post subject: Reply with quote

The Mack Maxidyne diesels (1960's and 1970's) used compressed bleed air from the turbo to drive a small air-powered turbine that drove the integral fan in the intercooler air-box. Nice design in that higher boost drove the cooling fan faster and vice versa. No pesky electric fan for the Mack, nosiree . . .
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PostPosted: Fri Feb 28, 2014 6:50 am    Post subject: Reply with quote

Hello all.. Just reading along and I have something a little different in my TDI set up that seems to be working well. I have my air intake on one pillar, in this case the right rear where the original intake was. Then i bring it across the back of the engine compartment to an air to air intercooler on the left rear pillar. I have an digital temp gun and I seem to be getting good temps. Air comes in hotter than it goes out the other side which is what I think I want. Now I know I cant pull that temp gun out while driving at 60mph and check but I have checked immediately after stopping and it still holds the variance. I had a variety of performance issues but it is running really solid now. I have added fuel coolers, oil and gear oil coolers in various places that have also helped. The shop just completed a new pipe from intercooler that has better bends in it but I seem to roll fine even during a summer day at 75 with the AC on. Not sure if this helps but it is my experience. If any one thinks this is flat out a bad idea and I can get better performance otherwise I would love to hear about it. I have the van off in at the shop for storage over the winter but i could have some pics sent ...
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furrylittleotter
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PostPosted: Fri Feb 28, 2014 6:17 am    Post subject: Reply with quote

OddN wrote:
[

I dont get it... You are making the intake air hotter by letting it cool the chargecooler. Wouldnt that equate to no additional cooling effect in total?


I was thinking the cool air introduced would offset the heating of the air going through the cooler. In other words, yes it would heat it, bit would also cool it, hopefully cooling more than heating it.

Maybe it would, maybe it wouldn't.


Wouldn't take much to find out if someone wants to try. I don't have a turbo so I can't or I would, but all my other ideas have worked out.

Neil2
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Zeitgeist 13
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PostPosted: Fri Feb 28, 2014 5:57 am    Post subject: Reply with quote

That's a classic hot air intake system...kinda self defeating. You want to draw your intake air ahead of the IC, or from the other pillar
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PostPosted: Fri Feb 28, 2014 5:49 am    Post subject: Reply with quote

furrylittleotter wrote:
goffoz wrote:
perpetual motion?


Not exactly, but I like where your mind's at. Wink

Here is a flowchart/diagram:

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


The beauty is the higher the rpms, the more flow and the more "precharge" cooling.

Neil2


I dont get it... You are making the intake air hotter by letting it cool the chargecooler. Wouldnt that equate to no additional cooling effect in total?
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PostPosted: Fri Feb 28, 2014 4:58 am    Post subject: Reply with quote

goffoz wrote:
perpetual motion?


Not exactly, but I like where your mind's at. Wink

Here is a flowchart/diagram:

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


The beauty is the higher the rpms, the more flow and the more "precharge" cooling.

Neil2
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Waldi
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PostPosted: Fri Feb 28, 2014 2:22 am    Post subject: my aircooler solution Reply with quote

Hi,
here u can see my solution in a 16 Syncro with AAZ and watercooled turbo.

https://fotos.web.de/ui/external/sI_-gRgXSgiY-kjJIa0RnQ96203

Feel free to insert the pics into ur awnser.
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goffoz
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PostPosted: Thu Feb 27, 2014 11:46 pm    Post subject: Reply with quote

furrylittleotter wrote:
I have a very simple solution to increase airflow through a pillar mounted intercooler; simply mount the intercooler, seal around it, mount a tapered shroud over it and connect your fresh air intake tube to it, that will draw fresh air through the intercooler, cooling it. Simple. Very Happy

Neil2

nice Very Happy perpetual motion?
Anyhow
..Fresh air intake is in the drivers side pillar, snorkeled.
... IC is on the passenger side, scooped.
....obstruction is the fuel filler(syncro)..it'll be nice to smooth the turbulence with some ABS or Al. ducting.
We'll see Confused
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