Any interest in a Front Mount Intercooler?

ZenProtege

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Mazda Protege Titanium 03.5
I recently recieved a few more mandrel bends for my custom FMIC setup.
At first, the goal was to replace whatever steel crush-bends I previosly had with mandrel aluminum ones, but I ended up changing the design of everything in the process.
I'm currently waiting on a silicone bend to arrive so I can complete the Turbo to IC piping, but other than that, its all been mocked up and should go together without a hitch.
The amount of piping I have rivals perrin's kit lengthwise, and is very direct.

To the point..
I know what bends are needed, the lengths of each, and the details of how to make my setup work. Ive looked around, and found a great intercooler and rest of the supplies for the price I wanted. If there would be enough people interested, I would try to make a few kits like mine or the piping for those already with intercoolers. I want to hear suggestions as to what you would or wouldnt want the kit to have(intercooler, piping, couplings,etc.) and see if there would be a market.

Most importantly of all, I want to make the intercooler kit or piping affordable. My goal is to make it competitive with any other available kit, at price thats several hundred dollars less. If I cant make it affordable, I wont attempt it.

Heres the setup I want to use = 500-600$

*Treadstone intercooler: bar & plate core (6 x 22 x 3.5) overall (6 x 28x 3.5)

*2.5 T6061 Aluminum piping

*3 ply polyester reinforced coupling (from turbo to TB will use approx. 7)
2 on IC, 1 turbo, 1 TB, 3 for piping

The way I have things will defiantly require cutting. The piping runs very similar to perrins, and the cuts are on the same piece of metal of the core support but lower(not in a structural area).

I don't know how well 2.5" piping will work either. I did my setup with 2" piping and had no clearance issues, but I haven't tried 2.5". I wanted to use 2" piping, but its much harder to find a good price on an IC with 2" entanks and piping.

Sorry for the rough paint drawing, but I don't want to post a pic of my car until the turbo to IC pipe has been completed


paintenginebay.JPG


bellintercooler.jpg


-Alex
 
It's not an idea, its somthing I have done.
This kit will have maybe, a 1-2" more piping than a SMIC with a much more efficiently placed intercooler. It's a much better choice than a side mount IMO.
 
I was thinking 2.5 would be to big for my setup,and my car is forged with a GT28RS turbo.

you may want to reconsider your piping size.
 
What size piping is used on other IC kits? I thought the other kits used 2.5" piping. It's good to hear reinforcement for 2" piping, Thats what I want to use.


Anybody have suggestions on what intercooler to use?
 
ZenProtege said:
What size piping is used on other IC kits? I thought the other kits used 2.5" piping. It's good to hear reinforcement for 2" piping, Thats what I want to use.


Anybody have suggestions on what intercooler to use?


2'' for the hot side / 2.5'' on the cold side. stock turbo outlet is 2'' and stock t/b is 2.5'' fyi
 
my perrin uses 2.5, i believe. they are huge. same diameter as the MAF and close to the same diam as the TB.

^just saw his post^
 
If you were hinting off to use two different OD pipes, I thought about it.

As far as clearance, it would def. work if I used 2" on the hot side and 2.5" on cold. Clearance isn't an issue at all on the TB side, but on the turbo side it gets close in one spot between the lower radiator hose and AC lines. 2.5" on the hot side would probably be a close fit on that spot.

Logic wise, The volume of the air is greater on the turbo to IC side than the IC to TB side because of the temp. difference. It wouldn't make sense to use the bigger piping to flow the air with less density/volume/pressure. So long as the hot side's piping is the same size as the cold side, there shouldn't be any restrictions
 
atticus1398 said:
my perrin uses 2.5, i believe. they are huge. same diameter as the MAF and close to the same diam as the TB.

^just saw his post^


the MAF is larger then 2.5,I have 2.5" on my MFIC with my MAF on a pressure pipe,considerably larger.I believe it's 2.75"
 
Sounds really interesting. Im sure you'll get more hits once you show your completed work. If possible a dyno result aswell..
 
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