Intercooler FAQ/Guide/Sticky

[1ViciousGSX]

I would like to hear from the shops, sponsors, vendors, and people with real world experience with this subject. I think there is a lot of great info out there, we just need to condense it down into something real. Several of you have plenty of experience with this already, so list up your choices based on what you would recommend. Base your recommendations on HP goals, price, flow specs, etc. Even if you are repeating what somebody else has said already, put in your $.02. This way we will see a real pattern of real data develope.

I'm not looking for sales sloggans, hype, magazine test data or people trying to push a certain product because it's what they sell. I also don't want to hear from Bobby's sister's boyfriend's 3 year old niece who knows somebody that installed "Joe-blows" FMIC and make 2500 awdawhp.

I would like to put together an intercooler guide that could be used in the FAQ's section of MitsuStyle to help the members make wise choices when looking into FMIC's.

Give as many specs about the FMIC as possible; 1g/2g/evo/3s, core type, core dimensions, cfm capability, pressure drop noted at what boost level and rpm, heat soaking properties, inlet vs. outlet temps, max power made at what boost level, etc. Even if you don't have all of the answers, say what you know (not what you think). Keep the discussion about the core, not the piping kit, mounting, etc.

Once enough data is gathered we should be able to put together some type of guide based on HP goals, boost levels, efficiency, price, etc.

If you think this is a waste of time, you can say so. But I think this would be something worth while for the FAQ section or just as a guide/sticky.

-1ViciousGSX

[AJ]

Great Mike, perfect topic to start the FAQ section in Forced Induction.

[rst95eclipse]

I ran a Johnnyracecar intercooler on my old RS-T. Dimensions were something like 20" x 8" x 2.5". It was bar and plate design. I expected the core to be good until 330hp without heatsoaking. I was only running 5lbs on e-manage and it ran for almost 2 weeks before getting slammed into, so I cannot comment further. I paid $100, since it was used. Yes, I know my "aluminized" piping is rusting. It's obvious it wasn't what was advertised and I should have at least put a coat of lacquer on it.

[niterydr]

Precision Turbo and Engineering Core. 12x24x4.5" core. 1300hp rating.
Bar and plate style, dense amount of turbolators.
Peak pressure drop was 3psi thru system. Average pressure drop was 2psi thru system. This is 36psi off turbochargers.
Max HP so far is 720.2awhp, 98.6 intake air temps with 95+ engine bay temps at turbochargers.
Heatsoaking non-revelant or apparent. Back to back 710+hp pulls result in 98.6 degree intake temps (3 back to back pulls done with testing, raising power each time. 705, 712, 720).
Retail price $1200 with in-house made aluminum endtanks.


Bell Intercooler technologies. 8.4x8x6" cores.
720cfm each. 4psi pressure drop combined. Heatsoaked at 620awhp.
Dense amount of turbolators, bar and plate design. 36psi off turbochargers.
Intake temps at end of 1/4 mile pass exceeding 200 degrees around 620awhp. Intake temps 150 degrees post dyno pull north of 600awhp.
Retail price $1299 bolt-in design with sandcast endtanks.

Design failure due to sidemount location and the inability to force air thru the cores.

[scheides]

Buschur Racing "Street" core/2G FMIC Kit. Measures 11x24x3.5" and was tested at <1psi pressure drop. I had this on my GSX w/ a bastard20G turbo. The car made 300whp (dyno dynamics) at 28psi and after 4 pulls the core was so hot it could cook meat on one end and cold on the other. Very efficient core, nice size as it seems to fit in a lot of places. Installation on my 2G required a lot of trimming, but I would buy it again as it comes with a nice set of all the piping needed.



I have this same core w/ different end tanks on my Evo, it is sold as the 'Deluxe' FMIC. Stock turbo w/cams it made 294whp @22.5psi (peak) on 92 and again, the core gets a little hot on one end but after about 4 inches it is cool to the touch. Best part was installation. I did have to trim two teeny tiny clips that hold on the very outside upper corners of the mesh in the stock bumper cover. It took about 5 seconds per side, very very very easy to install and fills the evo grill nicely.




snip these clips to get it to fit:

[Kevin 1G Drummer]

The '92 gsx I just got has a Dejon "Street" FMIC with short route piping. I don't know demensions, or core type, but it's pretty small. I tried looking on the Dejon site, but they didn't have any info for it. After a couple hard 3rd and 4th gear pulls, the inlet pipe was warm to the touch, and the outlet pipe was significantly cooler.

[x-pride]

Originally Posted by Kevin_1G_Drummer

The '92 gsx I just got has a Dejon "Street" FMIC with short route piping. I don't know demensions, or core type, but it's pretty small. I tried looking on the Dejon site, but they didn't have any info for it. After a couple hard 3rd and 4th gear pulls, the inlet pipe was warm to the touch, and the outlet pipe was significantly cooler.

I seen your core and it does not look like a Dejon core. Unless it was the first one that was release by dejon who welded two 1g core together. I could be wrong though. You might want to double check to make sure it is a dejon core.

[Jakey]

For those of you posting dyno-based intercooler numbers, did you have a fan sitting in front of the car? If so, what was the airflow rating of the fan? These posts need to be kept very specific otherwise the validity of this thread will go downhill in a definite hurry.

[scheides]

Good point Jakey. I've done multiple 1st through 5th gear runs on both of my cars and felt the I/C afterwards with the same results as what I described in my post above.

[niterydr]

Originally Posted by Jakey

For those of you posting dyno-based intercooler numbers, did you have a fan sitting in front of the car? If so, what was the airflow rating of the fan? These posts need to be kept very specific otherwise the validity of this thread will go downhill in a definite hurry.

Results posted for the dyno results are with a 15,000 cfm fan sitting infront of the fan, and I believe 2 3000cfm fans pointing towards the intercooler. These fans were not funneled exactly on the intercooler, but we were informed that they will simulate enough airflow for a car traveling at 60mph.

Track pulls and street pulls confirm the rest of the results.