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Kenne Bell 2.1 Intercooler [build log]
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<blockquote data-quote="mlackke" data-source="post: 16782665" data-attributes="member: 187511"><p>Finally back in business. Since last year I was not happy with performance of current intercooler, but in otherhand the core itself is from Ford Transit air condition heat exchanger which is not ment to cool massive heat from supercharger. It keeps small boost ..8psi~ with 93 under control, so alteast compared KB without this ,you are not running 200+ air temps in manifold. Anyway this lead that i wanted to use proper intercooler, however after long search i concluded there was no ready intercooler even with some fabrication i could use where price/performance would make sense.</p><p></p><p>So i ordered biggest intercooler from Bell what I could still fit inside KB manifold, this had almost 3x more capacity than current one and more than VMP Termi intercooler. Things looked good, expect once core arrived in September, i realized intercooler was too thick. Space after and before intercooler in manifold was quarter of inch and this probably would have limited the brick performance aswell the airflow. I had either options, buy 2nd intercooler, but less thick or raise manifold height, which would be very costly option.</p><p></p><p>Decided to go back to drawing board and I started to think why engine manifold sits so high eg compared to Termis and is there anything i could remove to lower it. And yes there is:</p><p>- IMRC plates > 1 inch added height</p><p>- Kenne bell manifold base plate thickness > 1/2 inch added height.</p><p></p><p>So removing these two, I could get 1.5 inch more space. Obviously I can't ditch the IMRC plates completely, because fuel injectors are attached to them and if I take bottom off from KB, I need to make new base plate between imrc plates,...so simply in nutshell I needed to build almost completely custom made manifold for new intercooler <img src="data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7" class="smilie smilie--sprite smilie--sprite9" alt=":eek:" title="Eek! :eek:" loading="lazy" data-shortname=":eek:" /></p><p></p><p>Bit of Budweiser and learning 3d-modeling in 24 hours, i came up this:</p><p>[ATTACH=full]1750901[/ATTACH]</p><p>Idea is that new intercooler could now completely rest top of IMRC plates (or maybe little space between) and bit of CNC machine work we can remove metal from IMRC plates allow air to flow.</p><p></p><p>However after having long discussions of fabrication, it came clear we did not have all required tools (such as tig welder), and expenses would increase significantly, partly since our lovely neighbour country leader decided to visit Ukrain <img src="data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7" class="smilie smilie--sprite smilie--sprite4" alt=":mad:" title="Mad :mad:" loading="lazy" data-shortname=":mad:" /> But this point, 3 years gone, finishing this no matter what <img src="data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7" class="smilie smilie--sprite smilie--sprite24" alt=":unsure:" title="Unsure :unsure:" loading="lazy" data-shortname=":unsure:" /></p><p></p><p></p><p>Anyway bit forward in time and about a month ago plates came and quick visit local CNC shop:</p><p>[ATTACH=full]1750902[/ATTACH]</p><p></p><p>...more to follow soon <img src="data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7" class="smilie smilie--sprite smilie--sprite1" alt=":)" title="Smile :)" loading="lazy" data-shortname=":)" /></p></blockquote><p></p>
[QUOTE="mlackke, post: 16782665, member: 187511"] Finally back in business. Since last year I was not happy with performance of current intercooler, but in otherhand the core itself is from Ford Transit air condition heat exchanger which is not ment to cool massive heat from supercharger. It keeps small boost ..8psi~ with 93 under control, so alteast compared KB without this ,you are not running 200+ air temps in manifold. Anyway this lead that i wanted to use proper intercooler, however after long search i concluded there was no ready intercooler even with some fabrication i could use where price/performance would make sense. So i ordered biggest intercooler from Bell what I could still fit inside KB manifold, this had almost 3x more capacity than current one and more than VMP Termi intercooler. Things looked good, expect once core arrived in September, i realized intercooler was too thick. Space after and before intercooler in manifold was quarter of inch and this probably would have limited the brick performance aswell the airflow. I had either options, buy 2nd intercooler, but less thick or raise manifold height, which would be very costly option. Decided to go back to drawing board and I started to think why engine manifold sits so high eg compared to Termis and is there anything i could remove to lower it. And yes there is: - IMRC plates > 1 inch added height - Kenne bell manifold base plate thickness > 1/2 inch added height. So removing these two, I could get 1.5 inch more space. Obviously I can't ditch the IMRC plates completely, because fuel injectors are attached to them and if I take bottom off from KB, I need to make new base plate between imrc plates,...so simply in nutshell I needed to build almost completely custom made manifold for new intercooler :eek: Bit of Budweiser and learning 3d-modeling in 24 hours, i came up this: [ATTACH type="full" alt="1654588185179.png"]1750901[/ATTACH] Idea is that new intercooler could now completely rest top of IMRC plates (or maybe little space between) and bit of CNC machine work we can remove metal from IMRC plates allow air to flow. However after having long discussions of fabrication, it came clear we did not have all required tools (such as tig welder), and expenses would increase significantly, partly since our lovely neighbour country leader decided to visit Ukrain :mad: But this point, 3 years gone, finishing this no matter what :unsure: Anyway bit forward in time and about a month ago plates came and quick visit local CNC shop: [ATTACH type="full" alt="1654588956779.png"]1750902[/ATTACH] ...more to follow soon :) [/QUOTE]
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Kenne Bell 2.1 Intercooler [build log]
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