Upcoming parts testing...

[JerseyDevil]

Hey guys, well our shop car just arrived so we will be busy in the next few weeks test fitting our Intercooler as well as doing extensive datalogging showing before and after AIT drops as well as Pressure drop and dyno data for the part. We are also going to do a bunch of testing on the factory intake system to see if it needs to be replaced in whole or in part. lastly we will be testing the factory electric bypass valve to see if it's leaking or not, in our experience on other vehicles using these type of valves, the valves leak and slow down spool/bleed off boost as they utilize a plastic piston on either a metal or plastic base. when you have a boost leak it creates a domino effect where the compressor has to work harder(lessening compressor efficiency and increasing pre intercooler charge air temps) and creates a thermal strain on all of the cooling systems(intercooling,oil and coolant) ultimately lessening overall power as well as the vehicles ability to maintain optimum power levels...

The ultimate goal is to fully max out the factory turbo(before we design our upgrade system) by eliminating/lessening pressure drops and leaks while also improving upon the factory intercooler in regards to keeping AIT near ambient which our Intercoolers we designed for the BMW,Mini, Abarth turbo cars are known for. We develop all of our parts through extensive testing and won't design something if it is not needed for a particular platform.

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[TurboAg]

Look forward to seeing results! Need more intercooler options

 

[JerseyDevil]

Look forward to seeing results! Need more intercooler options

heres a pic of our N54 BMW intercooler, this design has been used on stock all the way up to 600+hp 135/335i's(our ecoboost intercooler is quiet a bit larger) we are the only manufacturer that uses rounded ambient and charge row bars in our custom cores. using rounded surfaces in our cores and end tanks decreases pressure drops on both sides of the core. Our cores are custom to each application(we dont use off the shelf cores just because they fit)in regard to ambient and charge row heights and fin densities. we pride ourselves on producing world class parts, backed by extensive testing that work as well as they look!

heres an AIT trend datalog on one of our BMW coolers showing pre and post charge temps and how well our coolers drop and maintain cool intake air temps vs a stock BMW cooler:

 

[mbreinin]

Eagerly awaiting results!

 

[PewterCam]

Nice!! Can't wait to see what you will offer. I love how the EB mustang is attracting tuners from all corners of the automotive world.

 

[JerseyDevil]

Nice!! Can't wait to see what you will offer. I love how the EB mustang is attracting tuners from all corners of the automotive world.

We are Turbo people so you wont see us developing NA parts, unless the parts happen to work on the NA cars too. We have a combined 40+ years testing, tuning, developing and racing Turbo cars and have worked closely with GM and Mopar(don't hold it against us) back in the Sport Compact Drag racing days. Our cars and parts have also been featured in nationwide magazines, ultimate street car challenge and video games and we have developed products for some very well known tuning companies like AWE Tuning and Helix Motorsport

Each car is different in the fact of what the ecu wants to see to make and prolong maximum power, this guides us in direction for our prototyping then we apply sound engineering, proven methods and materials to meet our end goal with each part we design...We don't sell Fluff and welcome INDEPENDANT end user testing and comparison of our products.

If you guys want to learn anything turbocharging/intercooling feel free to ask, an educated consumer is who we target with our products

 

[DanFish]

Will you guys be using bar and plate intercooler? Where will the intercooler mount(if you know this yet)? Will you be providing upgraded intercooler piping?

 

[JerseyDevil]

Will you guys be using bar and plate intercooler? Where will the intercooler mount(if you know this yet)? Will you be providing upgraded intercooler piping?

Yes we use Bar and plate cores as shown above BUT we spec each according to application and also use rounded bar stock vs the usual flat bars that cause flow issues. The Ecoboost will be a front mount and will bolt up like factory BUT will have substantially more thermal reserve and a much larger ambient face. bar and plate is superior to tube and fin in a front mount location as it has a higher thermal mass and generally better entrances into the core(especially with our rounded surfaces), the only time tube and fin is superior is in a top mount situation where the intercooler is subject to engine bay heat(tube and fin due to its lower mass will generally cool off faster than a Bar and Plate-but will also heatsoak more quickly as can be seen with the factory tube and fin intercooler)

Here are pics of our rounded tube vs typical tube and fin vs typical bar and plate core:

Here is a pic of the affects on the shape entering the cores in regards to flow efficiencies, as you can see our approach with rounded edges(98% efficient) as far superior to traditional designs with typical Bar and Plate(80% efficient) and Tube and Fin(53% efficient) cores... This design is a lot more complex to fabricate as it adds several steps to the process but it's worth it...

We are also a producer of custom silicone charge piping and intakes, so expect to see an upgraded Intercooler hose kit and Intake(only if necessary, which we will find in our testing of the factory system) the factory intake looks from a design standpoint to be a really well thought out system with large diameter tubing tapering gradually to the compressor inlet, the airbox itself has a nice bellmouth built into it, as well as a large opening to the front of the car located in a high pressure area. There are some flat surfaces in the design that could possibly benefit from rounding out and making the box a TRUE ram air system and lessening pressure drop with a better flowing filter pays HUGE dividends once we get to the right side of the Compressor Map. BUT that's all the things we will find out through testing the system and maintaining strong points while strengthening weak points!

Here is a pic of our Abarth 500 Intercooler, custom silicone and Turbo Seal clamps!

Here is a pic of the CNC Velocity Stack we use on the Abarth intake with a corresponding cone inside the filter which gets the air moving correctly. We try to utilize rounded surfaces whenever we can because it makes huge differences in power especially when pushing a turbo to its max!

 

[DanFish]

Thanks for the info. Your n54 intercooler looks like it is built very well.

 

[Apwrx]

Excellent! Look forward to seeing your products.

 

[Swoope]

nice,

if you have the time i would love to know the advantages/disadvantages of a intercooler that has lots of front surface area vs one that surface area made up by the depth of the intercooler. ig tall and wide but thin vs short and square but thick.

hope that makes sense.. the stock one is second type mentioned.

beers

 

[PewterCam]

Wow!! fond this thread on one of the IC's you make for BMW's. Love how this is made with the multi-tiered design. Now I really look forward to seeing your IC for the EB.

http://www.1addicts.com/forums/showpost.php?p=17088274&postcount=1

I hope its available before the spring and the warm temps.

 

[JerseyDevil]

Wow!! fond this thread on one of the IC's you make for BMW's. Love how this is made with the multi-tiered design. Now I really look forward to seeing your IC for the EB.

http://www.1addicts.com/forums/showpost.php?p=17088274&postcount=1

I hope its available before the spring and the warm temps.

nice,

if you have the time i would love to know the advantages/disadvantages of a intercooler that has lots of front surface area vs one that surface area made up by the depth of the intercooler. ig tall and wide but thin vs short and square but thick.

hope that makes sense.. the stock one is second type mentioned.

beers

thanks for the compliments, we developed the Stepped Core concept back in 2006 and were also awarded a provisional patent pending on multidimensional heat exchangers. prior to this intercoolers were either square or rectangular, our cores and endtanks are designed to encapsulate the captive available space in any 3 dimensional shape. utilizing all available space allows us to customize the core in regards to fin density and ambient/charge row height so we can dial in the intercooler to meet the target ait/ait suppression and pressure drop.

now to answer the post on whats the best shape, that's a loaded question as we are bound by the space available to us-the target power level-and working in the frame of what the ecu wants to see. Generally speaking you want the intercooler to have a large ambient face and be on the thinner side as the cooling is most efficient on the face of the core and declines in efficiency the thicker the core gets(as the ambient air is heated as it travels through the core). a thicker core than stock can help to increase thermal mass(the weight of the intercooler plays a huge part in the way it heatsoaks and cools back off) as well as affect pressure drop. In our stepped core designs we can maximize the entire scenario of AIT/Temp suppression/Pressure drop by appropriately sizing the multidimensional core, the fin density, the ambient face, the endtank shape and ambient and charge row heights.

In the case of the Ecoboost we are utilizing a Stepped Core that will have a 750hp potential but will work perfectly on a stock car. we are also going to develop a Twincharger System and already have the second turbo spec'd out with a street boost power target of 500hp-500lb/ft. the secondary turbo we have specd can push 750hp worth of airflow at higher compound boost levels. we have twincharged several cars with great success such as the r53 mini(our daily driven twincharged mini has 360whp), and GM ecotec vehicles. the beauty of twincharging is the huge flat torque curve compared to simply going to a larger primary turbo. heres a pic of the twincharger kit we developed for Helix for the mini, the power levels are at the same boost levels ultimate AIT levels are less at much higher power levels when done correctly(there is a science to correctly pairing compound compressors on both the compressor and turbine side) compared to maximizing a smaller single turbo or supercharger...

 

[mbreinin]

Holy balls...you are going to compound boost the EB? I feel all tingly for some reason. LOL.

Will your IC be $800 like it is for the others I have seen you offer? Any idea of the target price for the compound boost "twincharger" setup?

Mike

 

[JerseyDevil]

Holy balls...you are going to compound boost the EB? I feel all tingly for some reason. LOL.

Will your IC be $800 like it is for the others I have seen you offer? Any idea of the target price for the compound boost "twincharger" setup?

Mike

We are targeting right around $800 for the Ecoboost IC, we hope to have some test fit/mock up pics today. We will know exactly where we are in a few hours as we are about to pull the front end off the car... Don't know price on the Twincharger yet as we need to get the testing on the entire system done to see what else needs to be upgraded... Cross your fingers that the intake and fuel systems can handle potentially 200 more hp, the less we have to change the lower the price will be.

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