Intercooling Bosch injected, non-chargecooled engine - Page 5 - LotusTalk - The Lotus Cars Community
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post #81 of 123 (permalink) Old 03-03-2016, 06:17 PM
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Yes, that doesn't look too cool. Can you use a rotary burr to remove part of the first fin inside?

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post #82 of 123 (permalink) Old 03-04-2016, 10:06 AM
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I'm thinking that if you had a Sharp, lubricated burr in a die grinder, you might be able to cut back the first few tubes without bashing back the edges, at least to get past the rivet that also blocks flow. I'm looking at other options for now, as this cooler only covers about 60% of the space available in my tray, but is too big to double up on.

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post #83 of 123 (permalink) Old 04-27-2016, 06:09 AM
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post #84 of 123 (permalink) Old 05-08-2016, 06:19 AM
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Quote:
Originally Posted by MRDANGERUS View Post
CC suction pipe inlet location. Tons of insulation applied.
I'm relocating cc return pipe to the "cold" side of the left fuel tank compartment wall.

Thanks Loren, excellent idea!

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post #85 of 123 (permalink) Old 05-15-2016, 08:21 AM
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CC pipe routing

Pictures show the "behind the wall" cc return pipe.

Drilling a hole in the wall requires a 1-1/4" thin wall hex drive hole saw and 90 deg adapter.
At this very awkward location there is only 3.5" clearance between the chassis and the wall [cross-car], making it impossible to use any conventional 90 deg drill head.
The rear edge of the hole has to be located slightly forward of the fuel tank forward edge to allow for 90 deg elbow insertion.
Pipe has to be insulated w/Thermo-Tec tape and a sleeve.
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post #86 of 123 (permalink) Old 05-22-2016, 07:52 PM
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Here is a final pipe routing, away from the scorching heat of the header.

This corner got really "crowded". I don't think I can stick a toothpick there.
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post #87 of 123 (permalink) Old 07-01-2016, 11:43 AM
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Routing of the coolant return from the CC to the pipes (1" OD) down & below (along the chassis tunnel).
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post #88 of 123 (permalink) Old 07-01-2016, 11:49 AM
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More pics. All pipes in the vicinity of the header are Thermo-Tec insulated. Section along the side of the tank received an additional Thermo-Tec sleeve. Instead of the sleeve, perhaps just a 1/2" thick foam pipe insulation would suffice, but clearance to the dividing wall was at premium.

Drilling a 1-1/4" dia hole in the wall requires a special equipment due to very tight space (limited by the chassis).
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post #89 of 123 (permalink) Old 07-27-2016, 07:12 AM
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An alternate way to mount the HE w/minimum plumbing.
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post #90 of 123 (permalink) Old 08-12-2016, 05:26 AM
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post #91 of 123 (permalink) Old 08-19-2016, 03:39 PM Thread Starter
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My intercooler has been working great. Intake is always barely warm to the touch. I will be installing the FrankenCIS soon to dial the tuning and be able to log the sensors to see what charge temp is. Currently the car warms up poorly, I assume because of the removal of the back pressure valve.

Next step is to relocate the oil cooler with a thermostatic sandwich plate. Was also thinking about relocating the miserable oil filter to a remote site. Either way, oil cooler will be much bigger, and on a thermostat so the oil always stays the right temp. It will also one less thing to be in the front charge cooler, oil cooler, condenser, radiator stack. I just have to find a place to put it. I was thinking two, one at the exit of each of the rear lower air ducts (brake coolers perhaps) or perhaps one on each side of the air ducts cooling the engine compartment.

Finally I could do a huge one at the exit of the engine bay below the glass, but I would need to measure the exit temp to make sure it is a cooler and not a heater.

Whatever the case, i am 99% sure behind the intercooler radiator is the wrong place to put it, especially with the distance the oil has to travel.

Any ideas?

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post #92 of 123 (permalink) Old 08-22-2016, 09:46 PM
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I'm facing the same dilemma.
Here is another possible location at the front.
A while ago, I bought 2 CSX Racing coolers
Air convection by itself won't be enough. Electric fans and thermostatic controller will be required. I may employ some low profile Delta 120mm case fans (w/reaction fins). They deliver 250CFM/ea; perhaps one fan per cooler will suffice.
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post #93 of 123 (permalink) Old 08-23-2016, 01:16 PM Thread Starter
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I'm thinking something like this run off the rear lower brake cooling duct, or perhaps off one of the upper airbox / exhaust cooling ducts.

I need to get my measuring tape out.

I really want to mount the cooler at the back of the car, using a sandwich plate with thermostat like this:



Or perhaps relocate the filter too so a screw on relocator like this:


Then a thermostat, a remote filter location, then a rear mount oil cooler with ducting



The goal being to keep the oil the correct temp, and minimize the distance traveled and the oil pressure drop. I think the thermostat sandwich plate, rather than relocating the oil filter, will result in the best flow, with the least restriction. An accusump could easily be added at the same time with an electronic valve hooked up to the ignition, to give instant and consistent oil pressure at all times.

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post #94 of 123 (permalink) Old 08-23-2016, 01:36 PM Thread Starter
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Or even better yet!!!



Put this water to oil cooler in the discharge side of the intercooler. My intercooler stays cool, so the water exiting it can't be more than say 120 degrees, which should keep the oil nice and cool too. Far less plumbing!

1988 Lotus Esprit Turbo
2002 Lotus Esprit V8 25th Anniversary #008
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post #95 of 123 (permalink) Old 09-19-2016, 07:13 AM
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These are Laminova tube coolers in disguise!

Most efficient HE devices invented since sliced bread, thus far.
Lightweight, effective, efficient, small!

Tubes used on Chevy Cobalt are only 8" long!
Two tube cooler would be sufficient for our Lotus 4 cyl. engines (two per bank for V8).

For more info, see:
http://97.74.32.155/files/intercool.pdf
Intercooler information - Build your own - Laminova
- Heat exchanger technology - Laminova



More great home brew:
http://forum.ih8mud.com/threads/1hdt...cooler.362684/
https://www.lotustalk.com/forums/f160...rcooler-73222/
http://www.millerwelds.com/resources...s/mboard/forum
http://forums.pelicanparts.com/911-9...injection.html

And a new type radial cooler HE:

http://www.lindseyracing.com/LR/Part..._PRODUCTS.html
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post #96 of 123 (permalink) Old 11-13-2016, 07:46 AM
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1" charge cooler line (blue) can be squeezed between radiator hose and a chassis member. Use common household items like KY jelly or hand lotion for lubrication during installation.

Last edited by MRDANGERUS; 12-09-2016 at 10:02 AM.
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post #97 of 123 (permalink) Old 12-09-2016, 09:57 AM
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Here is a picture after the nose brace installation.
I'm using OE V8 CC matrix, so my inlet is on the driver side.
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Last edited by MRDANGERUS; 12-09-2016 at 10:24 AM.
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post #98 of 123 (permalink) Old 01-22-2017, 06:57 AM
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Many other projects on the plate, so none registers fast progress.

Fuses/relays are required for CC pump and HE fans circuits. There is barely enough room to add both+temp controller.
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post #99 of 123 (permalink) Old 05-14-2017, 07:44 AM
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Esprit Hi Efficiency Intercooler Alternatives

Weight to performance ratio of the bar and plate intercoolers commonly available on the US market are quite abysmal! 17lbs, 6mm thick end tank walls is an overkill.
I’m thinking about making a custom liquid-air intercooler with the most efficient tube profile.
There are many alternatives!

1. ARE Cooling, Australia
ARE Cooling


2. PWR Performance Products
They offer a wide variety of lightweight tubular charge coolers/cores
https://www.pwr.com.au/portfolio/barrels-barbed-outlets

I'm sure there are others...

3. For example Mezzo went with micro-tubes https://mezzotech.com/why-micro-tubes/

Also, there is Intercooler_K&J_Hyde , which I've never heard about.

Everybody is claiming their product is "the best".
Is there any study to substantiate their claims?
I'm wondering, what profile (or manufacturer) offers the best performance?


My point: investigate performance and efficiency before buying low performance leviathan.

Interesting: Intercooler_K&J_Hyde

https://www.google.com/search?q=PWR+...ore+efficiency
.
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post #100 of 123 (permalink) Old 06-27-2017, 08:48 AM
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Dual section chargecooler = higher thermal efficiency, depending how you hook up the cold coolant flow.
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