Mazda Rotary Club

General => General Technical => Topic started by: chris@yoco on May 15, 2006, 12:46:28 PM

Title: fitted new intercooler over the weekend
Post by: chris@yoco on May 15, 2006, 12:46:28 PM
right guys

fitted my new intercooler this weekend but had to make parts for it to fit and also modify some aswell for it to fit the problem i have now is the HKS cones had to cut one pipe for it to fit in as lack of space not sure if this was the right thing to do as now 1 cone suck in alot of hot air from the twin turbo\'s and i also need more air feed to the intercooler check pics and see  :confused:  :confused:  :confused:  :confused:  :confused:

if you have any advise on what i can do please let me know

regards
chris@yoco

before i started
(http://i7.photobucket.com/albums/y264/scoobysnacks18/DSC01512.jpg)


(http://i7.photobucket.com/albums/y264/scoobysnacks18/DSC01513.jpg)

(http://i7.photobucket.com/albums/y264/scoobysnacks18/DSC01517.jpg)

(http://i7.photobucket.com/albums/y264/scoobysnacks18/DSC01518.jpg)

(http://i7.photobucket.com/albums/y264/scoobysnacks18/DSC01520.jpg)
Title: fitted new intercooler over the weekend
Post by: iaint on May 15, 2006, 01:12:53 PM
Couple of potential problems I can see from the piccies...

1) Move the filter from behind the intercooler.  It\'ll be breating air from the hottest point of the IC and efficiency will plummet - it\'s a feedback loop!

2) you\'ll need some form of ducting to get the air to go through the intercooler.  as it is the bulk of the air will flow round it.  It\'ll probably work a little better than teh stock one but you\'re not going to get close to the possible gains like that.

Iain
Title: fitted new intercooler over the weekend
Post by: chris@yoco on May 15, 2006, 01:40:41 PM
yep i know but not sure where to move the filter that is behind the the intercooler as there is not much space left i was think maybe exstending the pipes so the cones could sit more near to the front bumper
Title: fitted new intercooler over the weekend
Post by: AshRX on May 15, 2006, 01:49:08 PM
Chris, its a very tight fit to extend the filters. You just have to sit there and try and try to get them sit right. The problem is the bonnett shutting properly. They both do go in front of the IC but the bonnet dont close.

Skinny filters are the way to go on these
Title: fitted new intercooler over the weekend
Post by: chris@yoco on May 15, 2006, 02:00:53 PM
ok thanks for the help guys on the hunt for skinny filters
Title: fitted new intercooler over the weekend
Post by: davegttph1 on May 15, 2006, 02:37:40 PM
you noticed any improvement with the IC though? Do you have a PFC for before and after temps?
Title: fitted new intercooler over the weekend
Post by: chris@yoco on May 15, 2006, 02:42:39 PM
have noticed better torque but really need to get more could air in there could feel lack of power going the down the motorway from normal and have got a PFC but not really sure how to use the thing lol
Title: fitted new intercooler over the weekend
Post by: andyrose on May 15, 2006, 03:41:24 PM
Hi Chris
do you have a manual for your Apexi PFC?
if not give me a shout and i\'ll post you a photocopy
Regards
AndyR
Title: fitted new intercooler over the weekend
Post by: chris@yoco on May 15, 2006, 04:12:33 PM
Quote from: andyroseHi Chris
do you have a manual for your Apexi PFC?
if not give me a shout and i\'ll post you a photocopy
Regards
AndyR

Hi Andy

no m8 came with the car when i got it

a copy would be great m8

give us a email address and i forward my home address i tried to get one from theApexi web site wilth no luck
Title: fitted new intercooler over the weekend
Post by: Oedipus Rex on May 15, 2006, 04:44:05 PM
you might wanna try WGT they have a duct of their own design that comes with their uprated stock moun IC. They might sell you the duct seperately, worth a try.
Title: fitted new intercooler over the weekend
Post by: Andy_k on May 15, 2006, 07:39:53 PM
Chirs ask ash to send you a picture of how i done his, it is the best setup i could come up with for him.
Title: fitted new intercooler over the weekend
Post by: chris@yoco on May 15, 2006, 08:10:08 PM
Quote from: Oedipus Rexyou might wanna try WGT they have a duct of their own design that comes with their uprated stock moun IC. They might sell you the duct seperately, worth a try.

cheers m8 i give them i try
Title: fitted new intercooler over the weekend
Post by: chris@yoco on May 15, 2006, 08:10:48 PM
Quote from: Andy_kChirs ask ash to send you a picture of how i done his, it is the best setup i could come up with for him.
ok m8 thnaks
Title: fitted new intercooler over the weekend
Post by: chris@yoco on May 16, 2006, 10:12:04 PM
guys after fitting this intercooler will i need to get a remap on the apexi ecu
Title: fitted new intercooler over the weekend
Post by: iaint on May 16, 2006, 10:54:45 PM
Quote from: chris@yocoguys after fitting this intercooler will i need to get a remap on the apexi ecu

As a minimum have it rolling roaded to check you\'re not running lean.  Have the map tweaked if it\'s no longer safe.  Full remap might not be needed.
Title: fitted new intercooler over the weekend
Post by: chris@yoco on May 16, 2006, 11:13:53 PM
who would you would the best to do this
Title: fitted new intercooler over the weekend
Post by: oddball on May 17, 2006, 06:23:48 AM
Chris,  I have the same IC sitting in my loft at the moment.  Tried to fit it to my car but had the same problems as you except I have apexi twin cones so reverted to standard ic.  Please let me know if you find a way around the problem and what results you got from the ic.
Thanks in advance
Title: fitted new intercooler over the weekend
Post by: AshRX on May 17, 2006, 11:04:04 AM
The Apexi cones are an ideal fit. Keep the cones but you will need to get some longer tubing that flexs from the turbos.

The original air duct can be used. Need to cut about and inch all round so it fits snug with the IC
Title: fitted new intercooler over the weekend
Post by: Nobbie on May 17, 2006, 12:40:16 PM
Is there no way to fit it directly behind the bumper and just extent the boost pipes?
Title: fitted new intercooler over the weekend
Post by: AshRX on May 17, 2006, 12:46:55 PM
yeah if you get flexible hosing it should fit no problems
Title: fitted new intercooler over the weekend
Post by: Nobbie on May 17, 2006, 12:48:43 PM
I was thinking a couple of samco slight bends and the correct dia 304 pipeing, that way there\'s no problems.
Title: fitted new intercooler over the weekend
Post by: AshRX on May 17, 2006, 12:51:50 PM
should be good fit, the filters will fit perfect in front of the IC that way
Title: fitted new intercooler over the weekend
Post by: chris@yoco on May 17, 2006, 01:13:49 PM
Quote from: NobbieIs there no way to fit it directly behind the bumper and just extent the boost pipes?


thats what i am going to do looking out for some pipe now
Title: fitted new intercooler over the weekend
Post by: Nobbie on May 17, 2006, 01:18:54 PM
Best place is somewhere like a powerflow dealer, make sure its 304 though, that way it\'ll not corrode as easily.
Title: fitted new intercooler over the weekend
Post by: AshRX on May 17, 2006, 01:23:47 PM
or use Samco all the way, that way it will flex ok. You need to make sure the filters are as far forward as possible for cold air. Doing mine this weekend
Title: fitted new intercooler over the weekend
Post by: Nobbie on May 17, 2006, 01:32:11 PM
Depends on the amount of boost tbh.
Title: fitted new intercooler over the weekend
Post by: AshRX on May 17, 2006, 01:33:50 PM
yeah but as its stock turbos should be ok. Mine are running 1.1 bar on high boost and are fine
Title: fitted new intercooler over the weekend
Post by: Nobbie on May 17, 2006, 01:36:16 PM
Cool, something for me to keep in mind!
Shiney-ness is cooler though, lol
Title: fitted new intercooler over the weekend
Post by: AshRX on May 17, 2006, 01:38:58 PM
yeah agree there mate, just trying to find someone who can do it
Title: fitted new intercooler over the weekend
Post by: chris@yoco on May 17, 2006, 07:09:23 PM
yer going to use some chrome piping from demon tweeks and some samco joiners should work fine
Title: fitted new intercooler over the weekend
Post by: oddball on August 02, 2006, 08:49:33 AM
Chis,
I need the blanking plate for the flange where the blow off value would sit on the piping.  Did yours come with the kit or did you make one up.
Hope to be fitting mine on Friday.
Title: fitted new intercooler over the weekend
Post by: AshRX on August 02, 2006, 08:55:27 AM
Quote from: oddballChis,
I need the blanking plate for the flange where the blow off value would sit on the piping.  Did yours come with the kit or did you make one up.
Hope to be fitting mine on Friday.

I thought it was Saturday? :cool :driving
Title: fitted new intercooler over the weekend
Post by: oddball on August 02, 2006, 08:59:00 AM
Ash,  Saturday will be fine (I had it in my head it was Friday 4.th)  Any idea what time you may be here so I can strip it down ready.
Title: fitted new intercooler over the weekend
Post by: AshRX on August 02, 2006, 09:00:56 AM
early as possible, say 9.30 ok?
Title: fitted new intercooler over the weekend
Post by: oddball on August 02, 2006, 09:01:30 AM
Ash,  Did you get a blanking plate with your kit or make one up.
Title: fitted new intercooler over the weekend
Post by: AshRX on August 02, 2006, 09:04:02 AM
I had one made up from a garage
Title: fitted new intercooler over the weekend
Post by: oddball on August 02, 2006, 09:08:11 AM
OK mate I\'ll get onto that today.  Yep, 9.30 will be fine.  Will you be able to fing me OK
Title: fitted new intercooler over the weekend
Post by: oddball on August 02, 2006, 09:08:47 AM
find..................
Title: fitted new intercooler over the weekend
Post by: AshRX on August 02, 2006, 09:11:34 AM
got the tom tom already lol
Title: fitted new intercooler over the weekend
Post by: chris@yoco on August 02, 2006, 08:06:55 PM
Quote from: oddballChis,
I need the blanking plate for the flange where the blow off value would sit on the piping.  Did yours come with the kit or did you make one up.
Hope to be fitting mine on Friday.



hi m8

i made one up from alloy
Title: fitted new intercooler over the weekend
Post by: Fats on August 02, 2006, 08:55:38 PM
This one\'s to Ashrx, sorry if im bein cheeky, wot spec you running to get 395 bhp im looking to get into those sort of figure\'s just need a general idea, im running 285 fwhp with powerFC, decat and rear exhaust, panal filter, standard boost control and standard IC..

Cheers
Andy
Title: fitted new intercooler over the weekend
Post by: oddball on August 02, 2006, 08:56:04 PM
Thanks for the reply Chris.  Getting one made from stainless steel. Thanks again
Title: fitted new intercooler over the weekend
Post by: AshRX on August 03, 2006, 08:28:43 AM
Quote from: FatsThis one\'s to Ashrx, sorry if im bein cheeky, wot spec you running to get 395 bhp im looking to get into those sort of figure\'s just need a general idea, im running 285 fwhp with powerFC, decat and rear exhaust, panal filter, standard boost control and standard IC..

Cheers
Andy

Apexi GT 4 Row Front Mount Intercooler
HKS Blow off Valve
HKS Mega Power induction Kit
850cc Primary Injectors
850 cc Secondary Injectors
Air Pump removed
Alloy AST
Stainleess Underdrive Pulleys
HKS earthing Kit
Greddy Charging Stablizer
Stainless Induction and intercooler pipework
Uprated Fuel Pressure Regulator  
HKS EVC Boost controller set at 0.9 bar on low boost 1.1 on high boost
HKS 3" Downpipe
Trust Cat replacement pipe
Apexi GT cat back exhaust 5" tailpipe
Apexi FC ECU
Air Con removed
Uprated 10mm Magnecor Leads

Mapped on a cold day :Laugh
Title: fitted new intercooler over the weekend
Post by: Fats on August 03, 2006, 12:46:15 PM
Cheers mate!, i was in to minds to use 1300cc secondary\'s or 850cc primary\'s, did you have your fuel rail machined and standard secondarys fitted in the primary rail??
Title: fitted new intercooler over the weekend
Post by: AshRX on August 03, 2006, 12:47:53 PM
yes mate. Only running 70% injector duty too so plenty more still to come