Air water intercooler installed and tested

[idgtd]

So, in this thread:

http://www.vwdiesel.net/forum/index.php?topic=18881.0

I've been following my NA turbocharger install and subsequent operation. In the last post, I mentioned I had finished the install of the AWIC, and here it is.





And, I've done some testing on it. Although I'd like to increase my water flow to improve IC efficiency a bit more, the current numbers come out to about 67%.  This screen capture shows the different temperatures of the system during an acceleration run. Red is IC inlet temp, Green is IC outlet temp, and the blue line is ambient air, all in degrees C.




I've also logged the water temperature, and it never climbs more than a few degrees above ambient, so I'm pretty sure that my heat exchanger (modified A/C condenser) is up to the task.

So, now that she's turbocharged, intercooled, and has a 2.25" exhaust, I think it's time to work on the pump for more power.........



Thoughts, comments?

[truckinwagen]

very cool!
how are you logging intake temps?

I am thinking about doing the same thing, any idea how much $$ you have into the intercooling system?

also, what are you using as a pump?

[idgtd]

I'm logging the temps with a National Instruments data logger and thermocouples. One of the perks of working in automotive research 


As for cost, I got the IC from frozen boost for $150, and that was the bulk of the cost. The silicone couplers cost a good bit to. The rest of it was just fittings and hose. I'd say about $170-200. The pump is a mercedes aux water pump, which isn't really good enough for me but my friend had one lying around. I had a spare A/C condenser lying around, so I modified it for parallel flow and put it in front of the factory rad. and A/C cond.

It was more than I wanted to spend, but then again, it took no time to put it in since the IC piping was so simple.

[vanbcguy]

Awesome, that's pretty much exactly what I want to do to Jezebel!!

What'd you end up doing for a reservoir?

Oh, and do you have an additional fan on the heat exchanger, or are you just relying on the stock one?

[idgtd]

I used a 6" section of 4" pvc. I glued a cap on one end, drilled and tapped ports on it, and left the other end a slip fit. Works great!


No extra fan on my heat exchanger yet, and I don't think I'm going to put one on. The heat soak isn't really an issue thus far, but I'll keep monitoring it.

[vanbcguy]

I used a 6" section of 4" pvc. I glued a cap on one end, drilled and tapped ports on it, and left the other end a slip fit. Works great!


No extra fan on my heat exchanger yet, and I don't think I'm going to put one on. The heat soak isn't really an issue thus far, but I'll keep monitoring it.

That's an AWESOME idea... I was planning on trying to find a coolant overflow bottle or something, but the PVC pipe is a nice way to do it - smaller too!  Any idea how much water you've got in your system?

[truckinwagen]

not only that, but PVC would be the best way to make a reservoir for anything(like my water/meth system)

you could put a threaded end on it, so you could screw it down tight instead of just slipping the end on top.

-Owen

[Syncroincity]

I used a 6" section of 4" pvc. I glued a cap on one end, drilled and tapped ports on it, and left the other end a slip fit. Works great!

BRILLIANT!!

[CorsaCruiser]

Is an A/C condensor not too restrictive ? (any idea what the waterpressure is,
as these pumps are designed for low pressure, high flow.
Coupling between motor and impeller is magnetic (no direct shaft drive, and no leakage!))

Results look good, have you tried it on a long drive ?

[rodpaslow]

I'm on the fence between air and water IC.  I'd be interested in what it's like on a long drive as well.

Nice install!

[idgtd]

Is an A/C condensor not too restrictive ? (any idea what the waterpressure is,
as these pumps are designed for low pressure, high flow.
Coupling between motor and impeller is magnetic (no direct shaft drive, and no leakage!))

Results look good, have you tried it on a long drive ?

Originally the factory type condensor was too restrictive, so I TIG welded a fitting on it to divide the flow into two parallel paths. Now I'm getting about 1.5 GPM through it, but I'd like a little more.

The setup has been on quite a few longer drives, up to about 4 hrs. Works good, no heat soak!

[vanbcguy]

Hey, bringing this thread back from the dead since I'm close to doing a similar setup... So it's been over a year, still liking the AWIC?

[arb]

I'm on the fence between air and water IC.  I'd be interested in what it's like on a long drive as well.

Nice install!

as water can't cool charge air below 180F, air is more efficient on the highway, but it takes up more space under the hood and is not as efficient at low speeds w/o a fan...

Awesome piece of engineering work !!!  I didn't know there was much automotive research in N.H. :-D  I guess being at the big 3 for so long I missed it.

[blackbird82]

please explain why water can't cool charge below 180?  John Deere uses AWIC on a lot of applications. and we keep the water at 55 degrees fahrenheit in that system. 

[vanbcguy]

as water can't cool charge air below 180F, air is more efficient on the highway, but it takes up more space under the hood and is not as efficient at low speeds w/o a fan...

Awesome piece of engineering work !!!  I didn't know there was much automotive research in N.H. :-D  I guess being at the big 3 for so long I missed it.

Actually if you look at his temp charts you can see he is definitely cooling below 180F!  Looks like his peak post-IC temp was about 32C / 90F.

The place I've most frequently seen that 180F number quoted is when people are talking about using engine coolant for their AWIC setup which is definitely NOT what is happening here...