Upside Down Intercooler Piping

killfame

killfame

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Hello and Good Evening Everyone!

Silly question i know. I did a lot of research and picture investigation, but still can't assure myself.

What piping i exactly need for Upside Down Front Mount Intercooler
I'm about to put 600x300x76 Ebay Wellycooler on my Big Turbo Build atm

2x90 - 63mm welded to the cooler and then i'm stuck, not really sure about the right sizes of angle's
I want to "reproduce" Badger5 style, since my car is located in Bulgaria -where currently the work is progressed on (imported from UK)
And for that reason I do not have the opportunity to actually be mounted by Badger5 himself.

Sorry, if that's sounds unfair or disrespectful!
 
What is the advantage of fitting it like that ?.Extra cost in a hose bend, the bend off the intercooler has been fabricated so why not mount it the normal way up and make the bend tight to the car. Surely you would end up with the same fitting.
On the CFD diagrams I have seen for intercoolers usually you tend to get more flow through the part of the intercooler where the air comes in. Especially on the welly coolers where they don't have any flow directors . So I would of thought you would want that area in the best place for cool air flow which would be at the bottom.
I am sure there must be a good reason but just can't see it, other than it looks like a 3 inch hose system and possibly they fit better. But unless you are running big power most people use 2.5 inch with no issues.
 
desertstorm said:
What is the advantage of fitting it like that ?.Extra cost in a hose bend, the bend off the intercooler has been fabricated so why not mount it the normal way up and make the bend tight to the car. Surely you would end up with the same fitting.
On the CFD diagrams I have seen for intercoolers usually you tend to get more flow through the part of the intercooler where the air comes in. Especially on the welly coolers where they don't have any flow directors . So I would of thought you would want that area in the best place for cool air flow which would be at the bottom.
I am sure there must be a good reason but just can't see it, other than it looks like a 3 inch hose system and possibly they fit better. But unless you are running big power most people use 2.5 inch with no issues.
Click to expand...

Basically room or the lack of...

You can fit them the right way up but tends to either lose the fog grilles and/or push the bumper out too much

To get a decent FMIC fitted OEM style then realistically the AH V2 I designed will do that... however... welly coolers are cheap and very effective (assuming you get the proper non glued core ones) and to get it behind an S3 bumper OEM style this is the best way to go about it...

A FMIC needs to sit flush to the floor of the S3 bumper to allow the pipework to sit in the right place to not foul/lose the fogs and keep it OE looking...

Its been tested for pressure drop and there is no discernible drop across the charge air system fitting it this way and supports Bills 500+ hp builds with ease...

There are a few 63mm ended versions but they tend to either be smaller (less effective), special one off's (tricky to source) or glued core type (cr@p) but even then the ends don't sit low enough not to impact a clean fitment

<tuffty/>
 
desertstorm said:
What is the advantage of fitting it like that ?.Extra cost in a hose bend, the bend off the intercooler has been fabricated so why not mount it the normal way up and make the bend tight to the car. Surely you would end up with the same fitting.
On the CFD diagrams I have seen for intercoolers usually you tend to get more flow through the part of the intercooler where the air comes in. Especially on the welly coolers where they don't have any flow directors . So I would of thought you would want that area in the best place for cool air flow which would be at the bottom.
I am sure there must be a good reason but just can't see it, other than it looks like a 3 inch hose system and possibly they fit better. But unless you are running big power most people use 2.5 inch with no issues.
Click to expand...
because it does'nt fit and retain a std looking bumper with foglights still present.
toyo type B core this relates to
 
its gonna be even more difficult with the 76mm deep intercooler killfame bought and fitted 63mm inlet/outlet too. but most of the bulk of the intercooler is behind the number plate when upside down - isn't it?
 
I'm not looking for instant load of cool air, the car is used mainly for Fun and Relaxing myself from problems when i'm back home.
Upside down Front Mount, to me looks great. This idea suits my needs.
It's hidden much as possible. Since my intercooler is black, all my piping is gonna be black too.

The question is
4x90 63mm degrees alloy bends
4x90 63mm degrees silicone bends

Am I right?

PP: Fog lights are not a problem, i don't run them anyways.
 

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killfame said:
What piping i exactly need for Upside Down Front Mount Intercooler
I'm about to put 600x300x76 Ebay Wellycooler on my Big Turbo Build atm
Click to expand...

I can tell you what I bought for mine

Hot side (from upper IC pipe >):
1 x 60mm alloy coupling 100mm long
1 x 60-63mm reducing 90* silicone bend
1 x 63mm alloy 90* bend
1 x 63mm silicone 90* bend
1 x 63mm alloy 90* bend (cut and welded to IC inlet)

Cold side:
1 x 63mm alloy 90* bend (cut and welded to IC outlet)
1 x 63mm silicone 90* bend
1 x 63mm alloy 90* bend
1 x 63mm silicone 90* bend (to MAP pipe, if using std 60mm MAP pipe you will need 60-63mm reducing silicone bend instead)




Sent from my iPhone using Tapatalk
 
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S3 Hilife said:
I can tell you what I bought for mine

Hot side (from upper IC pipe >):
1 x 60mm alloy coupling 100mm long
1 x 60-63mm reducing 90* silicone bend
1 x 63mm alloy 90* bend
1 x 63mm silicone 90* bend
1 x 63mm alloy 90* bend (cut and welded to IC inlet)

Cold side:
1 x 63mm alloy 90* bend (cut and welded to IC outlet)
1 x 63mm silicone 90* bend
1 x 63mm alloy 90* bend
1 x 63mm silicone 90* bend (to MAP pipe, if using std 60mm MAP pipe you will need 60-63mm reducing silicone bend instead)




Sent from my iPhone using Tapatalk
Click to expand...

Fair enough, that's what i needed.

Thank you, soo much!
 
Has anyone tried replicating this but using silicone 90’s in and out of the cooler instead of the welded on hard pipes ?
Not necessarily to be better just easier !
 
basil brush said:
Has anyone tried replicating this but using silicone 90’s in and out of the cooler instead of the welded on hard pipes ?
Not necessarily to be better just easier !
Click to expand...
Bill has tried... You need 76mm to 63mm reducing elbows which aren't tight enough to route hoses where they need to go and then make the top part of the cooler push the bumper out...

<tuffty/>
 
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basil brush said:
Has anyone tried replicating this but using silicone 90’s in and out of the cooler instead of the welded on hard pipes ?
Not necessarily to be better just easier !
Click to expand...
bumper gets in the way.. 76mm silicon is 90mm outside diameter plus clip on a core which will already be pressed onto the back of the bumper from its 76mm thickness
 
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If you can get the airtec silicon hoses I'm sure there's a welly cooler a similar size. I couldn't find anyone supplying them. If they were 150 it would still be 150 quid cheaper.
 
Just a thought but why not just phone airtec and as them to sell you a set of the hoses in the colour you want. Tell them the hoses u have there is something wrong with and they might sell you the hoses.
 
Stuart B said:
If you can get the airtec silicon hoses I'm sure there's a welly cooler a similar size. I couldn't find anyone supplying them. If they were 150 it would still be 150 quid cheaper.
Click to expand...
If there was a welly cooler 'the right size' we'd all be using that instead of a welly cooler now wouldn't we :)

<tuffty/>
 
That's a puzzle Tuffty - I'm gonna stick to my muscle memory rubics cube.

HydroS3, I don't play well with others - if I call them I will be on the phone for hours with some convoluted digression of why I phoned them in the first place and then still hang up without actually asking the question I need to get an answer for. I phoned my own company help desk today because I didn't believe the support number on the documentation only to find it wasn't our company but a call centre 400 miles away who could direct me to someone at my company if I knew their extension number.
 
My mechanic came up with an idea and after short conversation, we end up with an decision. That's the way he did it, i'm really pleased how it came all together.
Bumper goes IN like a charm without single issue. We remove Headlight Washers I do not run them anyways. (Keep the covers only)
Headlight Ballasts gonna be relocated on the side of the Mask.
Usual Crash Bar cut and that's it.
He just Need to measure the sizes for the beautiful brackets that are coming on to hold the Cooler.
Next Thing, custom Tubular Manifold on its way for the Big Boy.

Welly Cooler 600x300x76
1x63mm Alloy 180 Degree Cut on Half
1x63mm Alloy (100mm Straight) Connecting Hot side
2x63mm Silicone 90 Degree
4xRacing Clamps.

Enjoy!
 

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That's such an excellent simple solution - it would be perfect for me as I don't have HID lights or the headlight washers - but in the UK if you have HID headlights the washers must work for the MOT. only a small amount of plastic trimming of the radiator surround too.
 
My MOT tester said that you only need washers with HID headlights on cars newer than something like 2010. Before that self levelling and washers may be fitted. If they are they must work.
http://www.autoexpress.co.uk/car-news/consumer-news/35636/watchdog-unfair-mot-failures

VOSA’s states: “A car with HID lights MAY also have headlight washers and self levelling which must be checked and in working order if fitted.

What happened top the AC radiator on that car in the pictures above. It looks very bent.
 
desertstorm said:
My MOT tester said that you only need washers with HID headlights on cars newer than something like 2010. Before that self levelling and washers may be fitted. If they are they must work.
http://www.autoexpress.co.uk/car-news/consumer-news/35636/watchdog-unfair-mot-failures

VOSA’s states: “A car with HID lights MAY also have headlight washers and self levelling which must be checked and in working order if fitted.

What happened top the AC radiator on that car in the pictures above. It looks very bent.
Click to expand...
Ignore it, I never had issue with it for 2 years, never bothered me since i own the car . Previously, little front end somewhere back in 2011 i believe.. Still original bumper etc..
 
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