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Quick Update, we've been optimizing the intercooler design. We've finalized on a great vertical flow custom Bell Intercooler co developed with RK and Bell. The original PWR design was very thermally efficient with the long horizontal channels, but those same long horizontal channels were very flow inefficient. This means we had to work the supercharger much harder and we were limited to about 7.5-8psi...
The horizontal a core has substantially better flow efficiency and much lower pressure drop, and we easily get to our 8.5-9psi target for the stage 2. I've also been doing some testing and we're seeing similar thermal efficiencies as the horizontal cooler. In fact on my cruise to Long Beach Washington down 101 (great highway for a drive btw!), I was seeing 7-8 degrees F over ambient at 65-70mph...
I have a track day coming up on the 20th and with my clutch issues now resolved I'll go do some check runs on the dyno for a quick remap and some fresh numbers.
Here's some pictures of the routing, eliminated a bunch of 90's coming out of the intercooler, even working on getting the brake duct's back on at least the passenger side!.
The outlet comes out very close to the bumper support, we use a silicone 45 to get a little give to go over it and put the bumper on without issues. The great thing is this piping fits right inside the bumper support, similar to how the stock intake piping runs!
Here's the pic from the front, nice and even, lots of core available in the cold air. Edges of the intercooler end right at the edges of the radiator, so that the air is directed through the stack of heat exchangers! We have plans to work on block off plates with brake ducts for the edges of the intercooler for those that are looking for the ultimate in temperature efficiency and to get brake ducts routed around the charge pipe on the drivers side.
We're finishing up the powder and the fan shrouds then the Stage 2's will be ready to ship, should be about a week to 10 days!
Quick Update, we've been optimizing the intercooler design. We've finalized on a great vertical flow custom Bell Intercooler co developed with RK and Bell. The original PWR design was very thermally efficient with the long horizontal channels, but those same long horizontal channels were very flow inefficient. This means we had to work the supercharger much harder and we were limited to about 7.5-8psi...
The horizontal a core has substantially better flow efficiency and much lower pressure drop, and we easily get to our 8.5-9psi target for the stage 2. I've also been doing some testing and we're seeing similar thermal efficiencies as the horizontal cooler. In fact on my cruise to Long Beach Washington down 101 (great highway for a drive btw!), I was seeing 7-8 degrees F over ambient at 65-70mph...
I have a track day coming up on the 20th and with my clutch issues now resolved I'll go do some check runs on the dyno for a quick remap and some fresh numbers.
Here's some pictures of the routing, eliminated a bunch of 90's coming out of the intercooler, even working on getting the brake duct's back on at least the passenger side!.
The outlet comes out very close to the bumper support, we use a silicone 45 to get a little give to go over it and put the bumper on without issues. The great thing is this piping fits right inside the bumper support, similar to how the stock intake piping runs!
Here's the pic from the front, nice and even, lots of core available in the cold air. Edges of the intercooler end right at the edges of the radiator, so that the air is directed through the stack of heat exchangers! We have plans to work on block off plates with brake ducts for the edges of the intercooler for those that are looking for the ultimate in temperature efficiency and to get brake ducts routed around the charge pipe on the drivers side.
We're finishing up the powder and the fan shrouds then the Stage 2's will be ready to ship, should be about a week to 10 days!
Jamie
The original post says 7.5-8psi.
Now you guys are saying 8.5-9 psi.
What kind of numbers are you expecting with the extra psi?
What kind of numbers are you expecting with the extra psi?
Thanks!
An extra psi at similar air density will give about 15-20 additional horsepower. I'll try to get to the dyno next week and see where we end up and if we need to add fuel or not...
Ambient temps are about 15-20 degrees higher than I tested before...
An extra psi at similar air density will give about 15-20 additional horsepower. I'll try to get to the dyno next week and see where we end up and if we need to add fuel or not...
Ambient temps are about 15-20 degrees higher than I tested before...
I did make it to the dyno and I only had time for 3 runs. Car was still adapting as the power was increasing with each run. Keep in mind the temps were about 15-20F higher than the last time we were on the dyno tuning... (40's before and now mid 60's...)
Car made 3 runs 509HP/433TQ Run 1, 512HP/439TQ and 516HP/436TQ Uncorrected. Made between 8.5-9 psi for each run at 7000 RPM or so.
I did make it to the dyno and I only had time for 3 runs. Car was still adapting as the power was increasing with each run. Keep in mind the temps were about 15-20F higher than the last time we were on the dyno tuning... (40's before and now mid 60's...)
Car made 3 runs 509HP/433TQ Run 1, 512HP/439TQ and 516HP/436TQ Uncorrected. Made between 8.5-9 psi for each run at 7000 RPM or so.
I did make it to the dyno and I only had time for 3 runs. Car was still adapting as the power was increasing with each run. Keep in mind the temps were about 15-20F higher than the last time we were on the dyno tuning... (40's before and now mid 60's...)
Car made 3 runs 509HP/433TQ Run 1, 512HP/439TQ and 516HP/436TQ Uncorrected. Made between 8.5-9 psi for each run at 7000 RPM or so.
Interior
B&M Short Shifter | ACS Pedals |MKIV Nav | Valentine1 1.8 w/Euro Pop Hardwired | Custom 3-pod Ashtray Gauges |
Not to far in the distant future Forged S62 **Looking for Le Mans Blue E39 M5**
--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- Stable
2009 R1 (rebuild in process)
2004 Imola X5 4.8is
2003 Cl500 AMG - Daily Driver
Sold 2009 550i Alpine White Sport M-Package
2008 550i Alpine White "Lemon"
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