Kenne Bell 2.1 Intercooler [build log]

mlackke

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Op, will you start fabricating these for sell?
Hmm, there would be lot of if's, starting if I would get enough orders that it makes sense...maybe.

Anyway WOT-test:
ambient 70-75F:
boost: 11.5psi~
14866390.jpg
 
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mlackke

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Ok, need to think about that, maybe then this prototype will be on sale bit cheaper than "production model";)

Anyway some update, so currently investigating high iats, few wot tests shows iats are 140-150 driving, 170-180f wot. Atleast now thinking/sounds that ic-pump is caviting and/or waterpipes has air what might explain unexpected high temps.
 

wildman97

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Ok, need to think about that, maybe then this prototype will be on sale bit cheaper than "production model";)

Anyway some update, so currently investigating high iats, few wot tests shows iats are 140-150 driving, 170-180f wot. Atleast now thinking/sounds that ic-pump is caviting and/or waterpipes has air what might explain unexpected high temps.

This project of yours have me a little excited, I would love to see this work for you and potentially for the rest of us 96-98 guys. Keep it up!
 

mlackke

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Thanks all the support :)

After some checking many things, pump cavitation, removing air from the system is not cause for high IAT, but IC itself. Water flows just fine through the system and when IAT's are hitting 150f-160f, water out from IC is max 80f, so something is not right.


So thinking either:

- Since IC- heat exchanger is self-fabricated and works as double-pass method:
>------|
<------|
Between the arrows there is small plate inserted what ensures that water goes all they way to end of IC-core and back. Suspecting that plate has come off which means soon as water enters to ic, it comes out and
only small portition of water is fully circulated whole heat-exchanger which would explain why it cools so little, but still warms up a bit.

- Fin-densitity is too large on heat-exchanger causing air going fully through it. Heat-exchanger is originally ment for turbo water-to-air where fin densitity is ...50% less that normal water radiators (eg Terminator IC-core). However as air needs to pass heat-exchanger TWICE before entering manifold, I doubt this could cause the issue based on temps.

- Air simply it not going through heat-exchanger. When air enters out from air-pipe "https://www.svtperformance.com/attachments/ed79vx9-jpg.1602207/" it is not 100% air tight, meaning 1-5% max of all air could slip out directly to manifold. But even such case i doubt i would see that high temps if 95% of air is really cooled down.

Result: Coming weeks need to remove the blower and open ic-box and test/understand what is wrong. So not giving up, but lot of work ahead to fix this. :confused:
 

ImThatGuy

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This is really cool and a neat fabrication job you have worked on. I am very interested to see the final product results, with temperatures and dyno numbers. Definitely be something I would be interested in to pick up another 96-98 cobra for.

If all goes well, maybe even combo it with some methanol or even the Killer Chiller setup for some stupids gains lol.
 

mlackke

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Some small update, so I decided slow down the pace a bit and actually get some miles for the car before summer is over and then get back to work :) However points I made previous post, I'm thinking either the Fin-densitity/Air flow "leaking" is currently the issue and already thinking to fabricate new ic-core for it...better one this time.

Yes i have thought about KillerChiller/Meth, but probably after this thinking to switch E85.
 

mlackke

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Well, i would want to make first sample fully functional before possible production...so no earlier than 2021.

In couple of weeks I should have something new to report...:)
 

mlackke

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Hello,

Quicky summary:

- I did give up temporarily for previous idea (IC in engine-bay). It needs more brainstorming how to fabricate it easy way. So 2021 back to this

- New IC, just top of Kenne Bell manifold. 2.5" thick, so need to order cowl hood.

- Due blower is now higher than earlier, lot of small issues popped up..cables in multiple places are getting too short, belt needs to be re-routed.etc. Easy fixes, but bunch of them.

Anyway enjoy the pics, tears and cash spend to create this :confused:

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mlackke

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Still missing few things, but decided to give a spin:
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So I wanted to measure some temps, but soon as I took car out, it started to rain. So I have to wait better day..not to mention that winter is again coming and roads are icy:(. Hoping to get still few dry days to collect some data. Meanwhile working on new pulley tensioner.
 

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