K turbo Watsons frame

[Chris16v]

How about using a charge cooler setup?

[geachy87]

Originally Posted by Chris16v

How about using a charge cooler setup?

Never used one but I'm just not keen on them for some reason, I'm going to fit an intercooler in where Darren did on his mini if there's the same amount of room on a 2 piece front end with the slam panel in the way



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[Cliff Pountney]

I think it distorted when welding. I was dropping the top surfaced of the frame where the lower wish bone bolts as I needed to make room for the gearbox to move to the left. All the work was on one side so I think it twisted.

Water to charge air coolers (WCACs) have some advantages but usually the disadvantages outweigh them.

Advantages -

• Charge cooler can be located anywhere so the charge ducts can be shorter.
• Launch can be better as they don't soak up to high temperature when stationary like air to charge air coolers (ACACs aka intercoolers).
• Less lag as smaller air volume between the turbo and the engine. Best designs integrate the cooler into the inlet manifold. (e.g.Ford 1.5GTDI and much of the VW range)

Disadvantages -

• They need a dedicated water cooling loop with its own pump and radiator.
• The total set up is typically 5 or more kgs heavier.
• The low temperature radiator needs to have a much bigger face area to match the efficiency of an ACAC as the inlet temperature difference is lower (Typically ~50degc compared with ~160degC for an ACAC)

Did I mention that I design engine cooling systems for a living

[geachy87]

Intercooler arrived today, there's plenty of room along the front and it'll get plenty air flow through the grille and I'll get the hole saw out along the front edge of the bonnet for extra flow to the top half






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[gadget555]

[twincamtone]

Wow! And I thought I had problems fitting a rad...Good luck matey

[geachy87]

Originally Posted by twincamtone

Wow! And I thought I had problems fitting a rad...Good luck matey

I had a few head scratching moments fitting the rad in with the old engine, things are just getting silly with this one, a lot of grinding and welding just to gain a few extra millimetres here and there

[twincamtone]

Know the feeling, looking a really neat job you're doing though

[geachy87]

Originally Posted by twincamtone

Know the feeling, looking a really neat job you're doing though

Cheers bud

[geachy87]

Slow progress on this at the moment, in the middle of rebuilding the box in my Astra which should be finished this week then I'll get back onto the mini










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[InstantCustard]

That’s not a happy bearing


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[geachy87]

Originally Posted by InstantCustard

That’s not a happy bearing


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Definitely not happy, wasn't a happy bearing in the whole box, bloody vauxhalls

[geachy87]

With the Astra finished it's time to get back onto this, I'll need to lower the radiator slightly so I can fit the intercooler to throttle body pipe in easier.
Also not sure if only mounting the intercooler by the two bottom lugs will be enough or could I get away with one bracket going from the bit of aluminium angle I have bracing the slam panel up to one of the top lugs on the intercooler just to give it extra support? Not sure if this would lead to the fibreglass front cracking over time or not?




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[geachy87]

Going to mount the intercooler to the engine now instead because I wasn't keen on the way I had done it before.
Started knocking up a bracket for one side..




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[geachy87]

Front end back on and it all still fits, I'll be able to do away with the little square I cut in the front panel now as well




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