Kenne Bell 2.1 Intercooler [build log]

mlackke

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So since reading so many threads and laughs about b-headed KB 2.1L does not have intercooler and it not possible create due engine valley spacing or whatever reason, I decided take the challenge :)

My first idea was to build like @mystickb1996 had created simple IC solution. However as KB kits sits so high in engine bay that adding anything between SC and manifold would cause that hood cannot be closed anymore. Yes you could always buy raised hood, but that would be (atleast to me) 1000$ expense...hood+shipping+taxes+painting.

Second idea was todo it like termis have, where @albino96 already had thread about it. However here the stock cobra manifold cannot be used because again stock hood could not be closed as it is higher than KB own manifold. Also i calculated the core wide should very narrow (more like 50% from original termi core) to allow air to flow properly. So thin core you would need to create eg airflow box under SC that redirects all the properly to core...and since there is again space issue, i decided that it would not be worth of effort.

So after brainstorming ideas and many hours later, fabricated following with my brothers help..hopefully images themselves do all the talking and you get idea how it works :)
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For now I have done couple test runs making sure air flows / car works as before with IC installed (no water circulating /any IC-piping installed yet). Next I would need to install IC-pump, reservoir, radiator, but due winter and other busy stuff is catching me up, so continuing this in spring :(. Hopefully then I have some temps for guys :)
 

jman37

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Looks pretty good. How long did it take you guys to fabricate that? I think eventually I will probably go the KB route, I'll keep you in mind!
 

mlackke

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Actually i expect this to perform close or even bit better than Termis IC-setup, but will see.
 

mlackke

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So winter is soon over here, though bit update this. I decided not to sit and wait whole time, but forge bottom end:

Last ride 2019:
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Drop engine:
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New parts from summit (Thanks UPS!!!)
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When starting cylinder honing process, I discovered it was quite impossible/very expensive to have torque plates...so fabricated them with my brothers help:
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Putting stuff together
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And now? Engine assembly still on-going, hopefully next post I have some updates of IC-part aswell :)
 

mlackke

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Have had a slow progress, delays and various small issues, but giving atleast monthly update:

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Inlet + Bypass mod. Thanks @venom1997 of idea :)
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Getting there...
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As build progresses always new and possible upcoming issues are raising, but so far no showstoppers. Maybe one i could tackle here, since IC water inlets are directly in front, the alternator is moved place of AC-unit which ment i had to buy longer belt, which is now 113". What i'm wondering here, how much boost...(well pulley rpm) you can run 6-rib? Currently i have main 6.5" + 3.25", so thinking how high i can go before noticing belt slippage?
 

mlackke

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Everything more or less assembled and time finally for first IC-test:

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Since tuning new motor remotely and only having first base-tune installed plus couple other small issues preventing WOT tests, but here is first results:

Driving 3-4th around 50mph

Ambient: 55
IAT: 125..130 (190-200 when IC pump off)

Atleast to me initial sign is good, however need to still perform some tests/calculations, eg IC-water inlet and outlet temps, IC heat-exchanger water inlet/outlet temps and based on those check if/what can be improved. Perhaps bigger heat-exchanger since current one core is bit small.

What else, biggest issue now is new belt which i purchased. It's surface is very smooth/slippery and every start my alternator squeals like mofo first 10s (belt slip) and then spins normally. Obviously higher rpm i would have again belt slippage. So need to tackle that by buying proper belt with friction.

Also i need to ditch my BBK CAI since does not work with new MAF, JTL CAI ordered.

And not sure is my bypass working correctly, need perform some tests with that aswell.
 

03cobra#2

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Most impressive! Very clean and good work. Initial iat temps are very good. Logging iat2 during wot will be the big test.
 

J.Rovirosa

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Nice work! If these ever come to market, I'll be in for a KB like most guys who never wanted the hassle of a Terminator swap.
 

mlackke

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New stuff from US:
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So status now:
- Belt problem resolved by Gates belt and JTL CAI installed.
- Currently trying to tackle where to get control current for IC-pump relay in engine...all stuff close to fusebox does not have enough amps turn the relay on :/
- Bypass seems to work some own tests but will see.
- Remote tuning still on-going, slow due time difference us<->europe, but so far no issues in tunes.
- Hopefully next week some kind WOT-tests and results.
- Dynorun (assuming everything goes perfect like always) late august.
 
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