Mazda Rotary Club

General => General Technical => Anything Engine/Performance/Tuning related => Topic started by: eyedee on September 18, 2004, 10:59:44 AM

Title: Intercooler Upgrade
Post by: eyedee on September 18, 2004, 10:59:44 AM
I\'m pretty new to turbo\'s cars, the RX-7 being my first and I\'m after more power.  I have already done the safe mods of Induction kit and Exhaust box, now I\'m looking for more power whilst still keeping the car drivable and without a huge bill.  So I guess the obvious next stage is to get a bigger intercooler, new breather hoses, uprated ECU, boost controller and guages, plus de-cat and get rid of the water pump as I wana louder exhaust note.  
What Intercoolers can you guy recommend, keeping in mind I\'m hoping to spend as little as possible.  I spose it would be cheaper to get an increased efficiency replacement intercooler as it doesnt involve moving bits round the engine bay, but I think a nice big intercooler would look wicked so I\'m up for that!
Also, whats the max boost setting you\'d recommend running with the above setup.
cheers all!  :cool
Title: Intercooler Upgrade
Post by: Donato on September 18, 2004, 12:09:54 PM
I take it you mean remove the air pump not the water pump..:eek: Otherwise your mod list will have to include a rebuild ;)

I have just done my ecu
put in a fmic
moved the battery to the boot
moved the rad to accomodate intercooler
and removed the airpump
new pipes etc..
decat and rear box

Believe me it wasn\'t cheap, and i fitted it all myself. By the time you add the cost of all the little bits like new coolant pipes etc it does all mount up.

It all depends on whether you can do the work yourself or if you need to get someone to do it for you? This can make a big difference to the final bill...

If your going to go ahead with it add a new fuel filter to that list. (a complete bugger to change but if you had seen the colour of the fuel that came out of mine you would know it was necessary.)

And depending on the size of intercooler you may have to look at uprated pump and injectors depending on what kind of boost you are looking for.

Cheers

Donato
Title: Intercooler Upgrade
Post by: eyedee on September 18, 2004, 01:36:22 PM
Air Pump, yeah.  :o   ;)   lol!

Hi Donato.  I\'m able to do most if not all the work myself, and I\'ve already replced the fuel filter (and yep, it def did need changing!)

Can I ask what intercooler you went for?  Im after something that will provide the maximum boost power gains without having to upgrade the injectors yet.  But still leaves me the option of upgrading the unjectors when I get my engine overhaul done (next year sometime hopefully).  I\'m not sure about the fuel pump - another thing I know very little about!  :confused:

cheers
Title: Intercooler Upgrade
Post by: Donato on September 18, 2004, 01:58:49 PM
Hi mate

I have fitted a Forge front mount.

I uprated the fuel pump as i also uprated my secondary injectors. If your not uprating injectors then you might not need the pump (check that with someone who knows!)

The best thing to do is speak to someone like Pip or Carl about intercoolers and the fuel requirements, i aint no expert!

Certainly with the intercooler i have extra fueling was required. (also because i changed the turbo\'s to non sequential one\'s ;) )

Here\'s a picture of the forge intercooler..

Cheers

Donato
Title: Intercooler Upgrade
Post by: Donato on September 18, 2004, 02:01:34 PM
And here is it all done with the expensive bits stuck in there! (no need to show you this one but im like a kid with a new toy with my engine bay! ;) )

Good luck with your plans
Title: Intercooler Upgrade
Post by: Fish on September 18, 2004, 04:39:32 PM
Donato, nice install. ;)

Fish
Title: Intercooler Upgrade
Post by: eyedee on September 18, 2004, 05:55:54 PM
That is really nicely done!  :cool   What did you do with your radiator mate?  Please excuse if thats a real dumb question!  Think I\'ll give Pip a call about the fuel pump!  Do you attend any of the monthly REX meets by the way?
cheers :D
Title: Intercooler Upgrade
Post by: Mark C on September 18, 2004, 06:06:42 PM
Ok so where exactly is the fuel filter as i may consider doing mine. Don\'t mind if it\'s just fiddley or an arse to do as long as it doesn\'t mean stripping down half the car to get at it.

Sorry for going a bit off topic.

Mark
Title: Intercooler Upgrade
Post by: Fish on September 18, 2004, 06:25:16 PM
Pig of a job. The filter is up on the rear axel.

Fish
Title: Intercooler Upgrade
Post by: Mark C on September 18, 2004, 07:50:02 PM
QuoteOriginally posted by Fish
Pig of a job. The filter is up on the rear axel.

Fish

REAR AXEL your having a laff, seriously?? might have taken a while to find it in the engine bay then :rollin , oh while i think will it piss petrol all over the place if i do have ago?

Thanks
Mark
Title: Intercooler Upgrade
Post by: yonner on September 18, 2004, 08:18:47 PM
it wont piss it but it will dribble a bit watch ur eyes :P

dan is that u runnign now m8?
Title: Intercooler Upgrade
Post by: iaint on September 19, 2004, 02:24:05 AM
Not seen it mentioned in this thread yet but if you\'re doing the intercooler, induction and de-catting you should also uprate the fueling system: fuel pump, fuel pressure regulator and bigger secondary injectors.

It\'s not a good idea to run the injectors at > 90% duty and with the mods you\'re proposing it\'s likely to max them out.

It\'s my understanding that one shouldn\'t put injectors in that are too big as at low duty cycle they won\'t atomise the fuel as well as in a sensible range.

I\'m in the process of uprating the intercooler on mine and will be sourcing 1200s for the secondary but leaving the 550 primaries in place to preserve mpg a tad.  You wouldn\'t need anythng bigger for the secondaries unless you go single turbo.

I\'d suggest the De-cat, ecu and mapping for 1st power upgrades as it\'s a good baseis for the next stage and won\'t break the bank.

Iain
Title: Intercooler Upgrade
Post by: <--rYaN--> on September 19, 2004, 02:51:11 PM
I\'m in the process of ordering a rather large V-mount intercooler/radiator kit, will relocate battery to storage bins for better weight distribution also, just need to get my fueling parts sorted and it will be spot on :cool
Title: Intercooler Upgrade
Post by: scooby_si on September 19, 2004, 03:21:47 PM
where\'s that from then rotary extreme?(http://smilies.jeeptalk.org/contrib/lynx/greydizzy.gif)
Si
Title: Intercooler Upgrade
Post by: <--rYaN--> on September 19, 2004, 03:50:16 PM
Thats the one! Not heard a bad thing about them (yet - touch wood) :D
Title: Intercooler Upgrade
Post by: Fish on September 19, 2004, 04:46:56 PM
Lets pray you dont have to much trouble fitting it.

Fish
Title: Intercooler Upgrade
Post by: Donato on September 20, 2004, 09:28:57 AM
QuoteOriginally posted by eyedee
That is really nicely done!  :cool   What did you do with your radiator mate?  Please excuse if thats a real dumb question!  Think I\'ll give Pip a call about the fuel pump!  Do you attend any of the monthly REX meets by the way?
cheers :D

Hi Mate,

Thanks.

Radiator is vertical just behind the intercooler. I have not been able to attend anything since rotorstock...looks like its next years events for me, monthly meets could get a bit expensive when you live in Edinburgh!

If you decide to go ahead then i can send you more pics info if you need..

Cheers

Donato
Title: Intercooler Upgrade
Post by: <--rYaN--> on September 20, 2004, 12:44:34 PM
QuoteOriginally posted by Fish
Lets pray you dont have to much trouble fitting it.

Fish

Why, are they supposed to be a pain in the arse to fit properly?? :confused:
Title: Intercooler Upgrade
Post by: 20B_boy on September 20, 2004, 01:31:42 PM
Lots of intercooler kits are a pain, i dont think its specific to the RE v-mount. And since no one (or hardly any one at least) has tried fitting one over here yet I wouldnt worry about it too much!
Title: Intercooler Upgrade
Post by: Fish on September 20, 2004, 02:15:58 PM
I am not sure, but just praying for you.

Fish
Title: Intercooler Upgrade
Post by: eyedee on September 20, 2004, 04:18:22 PM
Hello mate,

Hmm, yeah Edinburgh is more than a short throw away from my neck of the woods!  :rolleyes:   Thabks for the gesture of photos - might just take you up on that!

Ive seen a universal  intercooler (26" x 12" x 3.5") with the pipe connections at the top for a change, which is meant to take up to 500bhp.  Its about a third the price of the Greddy FMIC which is almost exactly the same size and looks pretty similar.  What do you recon?  Is there any reason I should buy a RX-7 TT specific unit?

cheers

Nathan
Title: Intercooler Upgrade
Post by: Donato on September 20, 2004, 04:37:14 PM
Hi mate,

I don\'t think Forge do a specific one for the FD and thats the make of my intercooler. I don\'t think it has to be FD specific. At the end of the day if you can get it to fit nicely into the airflow and the pipes are fitted and secure enough then you shouldn\'t have a problem when its mapped (again i am no expert so ask someone in the know)

Good luck with what you decide

No problem if you need photos or help, just give me a shout

Cheers

Donato
Title: Intercooler Upgrade
Post by: eyedee on September 21, 2004, 11:55:34 PM
Cheers Donato.  That\'s a great help.  I think I\'m gonna try and get myself an AFOS FMIC.  Pipes may be a little tight tho so I\'ll need to look more thoroughly at my options.  If I get stuck I\'ll give you a shout!  :D   Cheers again.