Just got my new Intercooler... Man I'm Siked!

[StingRayCrazy]

Man I'm siked! My buddy Marty Just finished my intercooler! I went over to his house last week wondering if It would ever get done and let me tell you, It was worth the wait. He showed up with it today all polished up and ready to go and said "Just don't stand there with your mouth open, lets get it mounted". The fit was just like my cardboard design. Its cool seeing a plan come together. Thanks go to my kindergarten teacher for the cardboard arts and crafts instruction. hehehe

The Intercooler will be forward of the motor laying flat between the frame extension and scooping up the air from under the car. Two 8" fans will also be mounted on top of both 10X12X5" cores. I designed a special 13” tall vertical radiator to fit in front of the Intercooler to keep things cool (still a work in progress and I'm not going to rush him). The hot air charge from the turbos will go into each side of the Intercooler and merge into the 4" outlet in the middle. A GReddy type "S" BOV will be fitted on the top of the Intercooler at the merged center section. Now I can get busy fitting and running the turbo plumbing. Here's a few pics to get a better idea of the setup. Happy Holidays to all you guys... :crazy

 

[silver 80]

very nice!!!

 

[qwall]

looks awesome

q

 

[StingRayCrazy]

Thanks guys, I love the sparkel of polished aluminum... :crazy

 

[qwall]

i want 1 too...... along with tt

q

 

[GerryLP]

Very cool indeed!!!! No pun intended. I would suggest placing a patent on that baby -unless you borrowed the design...:L

 

[69MyWay]

You do realize, you are my living hero, don't you?

Wow! This is outrageous.

You know, you really, really, really, really, need to look into the L88 body mods so that you can stuff more rubber under the back like my car, TZracers, and Merlin. You will need that rubber to hold that son of a gun to the ground. Heck, I think you might have to check with air traffic control before leaving your driveway!!!!!


Will you have the exhaust just quite enough that the whirl/whine of the turbos will easily be heard?

That is one of the coolest sounds, especially coupled with a pair of pop off valves.

 

[69MyWay]

One other thought I just had, has to do with the radiator. Obviously you are going to have to get really trick to get that in there and work now that the coolers are taking up that space. Have you thought about some slight firewall mods and simply pushing the engine back about 2-3" to the back of the car? I know it can be done, and It seems like that would give you better weight transfer, as well as a little extra room to play up front.

Just a thought.

 

[MaineShark]

Looks very good.

While on the subject of modifications, and while it is still accessible, you might want to consider welding and tapping some mounting points to allow you to install air temp sensors on each inlet, and the outlet. You will be able to monitor the efficiency of the intercooler, and having one on each inlet will allow you to monitor the balance between the two turbos... if the temperature difference between the two is large, you will immediately be aware of a problem.

With a bit of wiring and mechanical assembly, you could create a diagnostic display, with guages for the exhaust temp, temperature at the outlet of the intercooler, and the average of the two inlet temperatures, with a warning light to tell you if the two temperatures differ by more than a certain amount.

Actually, with all the modifications you are making, a cluster of diagnostic gauges (hidden in the dash storage compartment in front of the passenger seat, perhaps) might be a good idea. Either that, or wire all the sensors to a plug in that compartment, and create a portable unit with guages for all the sensors, that you can plug in when diagnosing a problem. If it were me doing it, anyway, I'd put sensors on everything I could think of, to track down problems quickly. And, to help with tweaking and tuning.

I'm curious, did you consider air-water intercoolers? They are a bit heavier, and more complex, but might be easier to work into the cramped engine compartment of a 'Vette. I may build a supercharged 'Vette in a few years, and I think that's the route I will go. Still, that air-air unit looks awful nice, and might actually be better for the twin-turbo setup.

Joe

 

[StingRayCrazy]

Very cool indeed!!!! No pun intended. I would suggest placing a patent on that baby -unless you borrowed the design...

Gerry, Nope it’s my design and that’s in the works, Thanks... :crazy

Chris, man I wished you up here close to Syracuse! I wouldn’t have any problems then... I'm scared to death of body work, that’s an art I leave to you professionals. I've got the ZL1 one piece tilt front end and matching rear flares, I just need to get them installed.
I have a question for you though, should I have the body work done off of the frame or should I wait until the body is back on before I have the flares installed? I also thought about moving the motor back but @ 6'3" I need all the leg room I can get. Don't worry I still got plenty of room for the goodie’s up front. Here is my radiator design you were asking about. :crazy

MainShark, I've got that one covered. You must be a mind reader. I'm going a little over board with it however, I just hope it goes as well as I’ve planed. I'm a Controls Engineer by trade and I carried my trade over to Crazy by building an onboard 1 GHz PIII data acquisition PC. I plan on using "K" type thermocouples on the inlet and outlets of both turbos exhaust housings as well as the compressor discharge temps and throttle body inlet temp. This way I can vary the waste gate adjustments to make sure both sides are balanced. I also plan on measuring the delta across the exhaust housings monitoring equal compressor load and to find out the boost to back pressure ratio. I'm using National Instruments, "Labview" (software) and a NI PCI-1200 data acquisition board (hardware) to build the control logic interface screens and trending plots. If it works out the next step will be to build a PID controlled stepper motor boost controller. We will see... :crazy

here is a link for the PCI-1200
http://sine.ni.com/apps/we/nioc.vp?cid=5497&lang=US


Merry Christmas you Guys!

 

[69MyWay]

The flares should really be done on the car on the frame.

Believe me, if you have the patients to think through and work through your turbo motor, you have more than enough skill to do the body work.

Remember, there is virtually nothing you can't grind back down and start over. Bondo fixes everything!

I think you can do it, and the sense of accomplishment is priceless when completed. It can also give you hours of quiet time (while you are block sanding) to think through your next set of mods.

You can bet that I would be more than willing to pitch in if we were geographically closer, but that does not mean I can't support you from a distance with e-mail, photos, and even a phone call if you need it.

 

[Stallion]

Is this the part of the Vette which is the "grill" for the airflow to cool down the block? Is that what it's for, to cool the block off? If not, then what?

Thanks!

Good luck with the mod!

TR

 

[MaineShark]

StingRayCrazy: Sounds about like what I would do, if it were my car. LabView is a nice program, and the ease of creating professional-looking graphical interfaces makes it fun to show off - people tend to think you must be some sort of computer genius to create all those digital buttons, switches, knows, dials, meters, etc.

Just another thought: with an on-board computer, and your obvious level of experience, you might want to consider a HalTech E6K - it will allow you control over both fuel and spark curves, and its 12 injector outputs could be set up with 8 for the cylinders, and 4 staged to come in with the boost, to reduce the duty cycle of each individual injector (which results in more consistent fuel metering).

Stallion: An intercooler is not normally part of a Corvette. StingRayCrazy's car is a project, with turbochargers added. When the turbocharger compresses the air, it heats it up. Since cold air is better in the engine, the intercooler is placed in the system, between the turbochargers and the engine. The air will enter from the two turbochargers in the pipes on either side, go through the "cores" and exit through the single center pipe, then head up to the engine. Just like the radiator cools the water, the intercooler cores cool the air. In the pictures where it is installed in the frame, the piping will go up to the blue-and-red connector at the top. The turbochargers will be mounted on either side of the engine, and have pipes that go down to the two inlets on the intercooler. If you check out StingRayCrazy's site, he has more information about the project.

Joe

 

[StingRayCrazy]

MainShark, I looked at the Haltech, which will be an option if the Holley MPI ECU doesn't work out. Have you seen the AutochartPro software for the Holley ECU? You can go to www.autochart.com and download the demo. I have the latest version which includes data acquisition, control over both fuel and spark curves and a neat auto analyses feature that can tune your fuel map by reading the recorded O2 data. I can't wait to get it running and check it out. I would like to get your opinion on it if you have the time.

http://www.autochart.com/highlights.htm

Thanks :crazy



Stallion, MainShark hit the nail on the head...

 

[Stallion]

Okay, I understand what you mean. So with this "turbo" engine, air will be forced into the block for a more powerful (more hp?) ride? I see! Thanks!

TR

 

[RLP]

Very nice, It will sound like a Cart Champ car when the blow off valve lets off pressure when you shift or slow down.

 

[Shark Chief]

I checked out your website, you got some crazy lookin VETTE-RODS. :cool

 

[Stallion]

Very nice, It will sound like a Cart Champ car when the blow off valve lets off pressure when you shift or slow down.

What would this mod do to the sound of the Vette and why? Because it's turbo, would it make the engine sound different? And how?

TR

 

[MaineShark]

StingRayCrazy: I'll have to take a look at that. The automatic tuning with the O2 sensor seems like a nice feature, to get a base map to fine-tune from.

Stallion: When you let off the gas pedal in a turbocharged car, the turbo keeps spinning for a little while, producing boost pressure. Since the engine is already going slower, this is a problem, as it doesn't need the extra air - the extra air would create excess pressure). So, a blow-off valve lets air escape when it gets beyond a certain pressure. The hiss of a blow-off valve is a distinctive sound. Some people actually attach devices that work like whistles, to turn the hiss into a note. Personally, I think the hiss is a better sound.

Of course, even when running normally, the turbochargers make a distinctive sound of their own (the core spins at tens of thousands of rpm - up to over 100,000 in some turbos), as does the air flowing through the intake piping. The exhaust note is also different, since it has flowed through the turbocharger's turbine section.

Joe

 

[Evolution1980]

Honestly guys, I don't think I can ever recall really hearing the sound of turbos on a car, or the blow off valve. I know the supercharger whine, but not turbos. Anyone have any sound clips anywhere?