Intercooling Bosch injected, non-chargecooled engine - Page 2 - LotusTalk - The Lotus Cars Community
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post #21 of 123 (permalink) Old 02-04-2015, 05:53 AM
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post #22 of 123 (permalink) Old 04-21-2015, 08:55 PM
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Xtrax,
How are you doing?

FYI:
Here are some good, bad and ugly chargecooler pump characteristics
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post #23 of 123 (permalink) Old 05-04-2015, 06:13 PM Thread Starter
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Well my cylinder head just got back from the head shop, and my motor is almost back together. Just got my valves dialed in today, so I am going to button the rest of the motor up this week and hope to drop it back in this weekend. I have had a couple of work related delays that have kept me away from the project, and now I have a major motivation to get it done.

I sold my house, and I am moving at the end of this month. If I don't get this car running in the next couple of weeks I will be towing it to my new home, and pushing into the garage. That is no way for an Esprit to enter a new neighborhood.

One way or another, I need to finish it in the next few weeks.

I will keep you guys posted.

1988 Lotus Esprit Turbo
2002 Lotus Esprit V8 25th Anniversary #008
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post #24 of 123 (permalink) Old 05-04-2015, 06:15 PM Thread Starter
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Oh yeah, and the show House Hunters filmed at my house a few weeks back. There may be a (dirty) Esprit in the show if they filmed the garage at all. I guess we will see in the coming months.

1988 Lotus Esprit Turbo
2002 Lotus Esprit V8 25th Anniversary #008
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post #25 of 123 (permalink) Old 05-04-2015, 07:28 PM
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post #26 of 123 (permalink) Old 05-05-2015, 09:22 AM
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This is my 1987 HCI with intercoolerAttachment 546057
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post #27 of 123 (permalink) Old 05-05-2015, 10:09 AM
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Nicely done!
I like how you relocated the oil filler cap too as the original cap on the Bosch cars is usually where the intercooler now sits.

Do you have any threads or website detailing this retrofit of a factory intercooler to a Bosch injected Esprit?

Roy

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This is my 1987 HCI with intercoolerAttachment 546057
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post #28 of 123 (permalink) Old 05-06-2015, 09:25 AM
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Sorry Roy this was done before I purchased the car. I did however have an aluminum insert and the oil filler cap welded into the spot where the old plastic oil filler cap was. I couldn't get hold of a new plastic cap Bought the insert from RD Enterprises
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post #29 of 123 (permalink) Old 05-06-2015, 10:57 AM
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Beautifully done!
Thanks Watership

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Sorry Roy this was done before I purchased the car. I did however have an aluminum insert and the oil filler cap welded into the spot where the old plastic oil filler cap was. I couldn't get hold of a new plastic cap Bought the insert from RD Enterprises
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post #30 of 123 (permalink) Old 05-18-2015, 07:12 PM
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post #31 of 123 (permalink) Old 05-20-2015, 08:56 AM Thread Starter
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I am back on the road folks, and running great. New forged pistons, full head job with some new valves, and all new bearings / seals / etc. Took longer than I had anticipated, but thats the way it works some times. I move in 2 weeks to my next home (3 car garage finally). Custom built a 3" 304 stainless exhaust for the car as well. I am finalizing the exhaust hangers, then I will take some pictures. I also added a grimmspeed manual boost controller, which I highly recommend. The car builds boost way faster. Now I just have to be patient during the break in period. I have adjusted it to the stock level of boost, but instead of gradually opening the waste gate as the car builds boost, it leaves it closed until full boost is achieved, then opens it.

Next step is the FrankenCIS. I am going to give that a try, as my lambda ecu is unreliable, I want more control over fueling, and I can't seem to leave good enough alone.

I am having some cooling issues, most likely due to my intercooler heat exchanger stacked in front of the AC condenser, stacked in front of the radiator, all behind the oil cooler. Car runs about 85C on the highway, but after about 20 miles it starts to creep up to about 90-95C. This is with the AC on full blast. Once I hit traffic it does fine and fluctuates between 100C and 90C. Hasn't overheaded yet, but I only have about 50 miles on it. I am thinking I will remove the fog lights to see if it is a intake area issue, or if the heat exchanger core is too thick to be stacked in front of the radiator. I also put the oil cooler standing vertical right in front, as far forwards as it goes, so that could be blocking some cooling air by not allowing for enough ducting room, and diverting the air flow.

1988 Lotus Esprit Turbo
2002 Lotus Esprit V8 25th Anniversary #008

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post #32 of 123 (permalink) Old 05-20-2015, 09:18 AM
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Congrats...


Regards cooling...perhaps you have discovered the reason that Lotus used two small oil coolers on either side of the air intake? That way the majority of the air still is directed to the main radiator and A/C. (Is your refrigerant blend still working well?)

How 'bout some pics of the exhaust you made?

Atwell Haines
'88 Esprit
Succasunna, NJ USA


"Not all angels have wings." - Turbo R
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post #33 of 123 (permalink) Old 05-20-2015, 10:40 AM Thread Starter
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Yeah, I am trying to avoid buying new oil coolers, especially given their "strange" fitting types. It may be a necessity. I don't like where it is mounted, but had few options.

I will take pictures of the exhaust once it is done. i did a v-band clamp to the downpipe, which is a really neat, gasketless connection.

A/C still blows as cold as I understand I can expect it to, which isn't freezing anyone (other than a knee) but it works in our hot weather. I am intending to return to R12 one of these days. I have to buy some first, and I want to make sure I have no leaks and no reason to disassemble the A/C system again.

1988 Lotus Esprit Turbo
2002 Lotus Esprit V8 25th Anniversary #008
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post #34 of 123 (permalink) Old 05-20-2015, 10:54 AM
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The centrally located oil cooler on some earlier cars (rather dumb idea), can be removed and replaced by two smaller coolers in the wings.
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post #35 of 123 (permalink) Old 05-21-2015, 08:10 AM Thread Starter
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Do you have a suggested oil cooler setup in mind?

1988 Lotus Esprit Turbo
2002 Lotus Esprit V8 25th Anniversary #008
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post #36 of 123 (permalink) Old 05-21-2015, 08:03 PM
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8"x 5" (6" max) coolers. I got them on eBay at CX Racing a while ago. They have 1/2" NPT female fittings allowing use of large banjos or tight radius 1/2" NPT to 3/4" hose elbows. The fan on the picture is 5" SPAL, but recently, I spied out some low draw, v. powerful 120mmx120mm square server fans (200 CFM each). Fittings will be stainless (not brass!)
I have to design some kind of a scoop, bottom intake. This project may have to wait a while.
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post #37 of 123 (permalink) Old 05-22-2015, 04:55 AM
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We have worked on a car (Artie B's) which placed the oil cooler in the rear of the car and ran two 4" Spal-type fans. He had converted the oil cooler (the car was originally a 1989 non-SE) to act as the radiator for the added-on intercooler. We did not have extensive driving experience with the car but the set-up seemed to work pretty well. If I can find some pictures I will post them.

Tom Mieczkowski
1989 Esprit Turbo
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post #38 of 123 (permalink) Old 05-22-2015, 06:00 AM
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I added Jabsco Cyclone pump to the chart. Impressive small (relatively) pump.

120x120 server fans- here is the picture
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post #39 of 123 (permalink) Old 05-22-2015, 07:47 AM
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Inexpensive DIY version of the "Alunox" intercooler

No need to spend big bucks!
You can make a perfectly good charge cooler for less than $300 by cutting and welding two 9"x4.5", 3.5" tall inter-coolers together.

DO NOT buy any ready made 4.5" thick CC, because you won't be able to fit it under the engine cover. 3.5" is the max!

Source: eBay
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post #40 of 123 (permalink) Old 05-22-2015, 07:54 AM
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