JRSC Intercooler Project

[99SIVTEC]

I figure this is the place to post this instead of Club SI. Hopefully you guys have some good suggestions. I've done all of my measurements and I have room for a 1 inch thick membrane intercooler on the civic si. This mounts between the manifold and blower for those not familiar with membrane intercoolers. The idea is siimple, cram a radiator type heat exchanger between the manifold and blower. The blower pressurizes the manifold and the charge of air is cooled by the air/water unit. Being only 1 inch thick presents some problems for surface area, so I got creative. The core is all copper and is actually 2.5 inches thick. I've seen a similar sized setup on a V8 net over 40 hp at 9psi on a 300 hp motor. Now the rest of the system is pretty simple, you have a water reservour that you can fill with ice water or whatever you want. This is pumped by a 12 volt electric pump to the intercooler where it is circulated and heats up. It then exits the IC and goes on to a small oil cooler to cool the water back down before going back into the reservour. Very simple yet effective system. Afterall the limiting factor in the amount of boost we can make is not the blower, but in fact the outlet temps. The blower itself can safely spin at up to 14,000 rpm. Now with an 8000 rpm redline thats nearly 41 psi of boost, which no amount of intercooling is going to allow you to run, but 15-20 psi safely on a daily driver seems like a reasonable goal if the core is efficient enough. I'm going to use the hondata phenolic manifold gasket so the engine isn't heating the manifold as well.

I've got the prototype solid model pictures over at my site. I've already got a machinist that will make the plate and core, as well as a welder for the rest of the stuff. The machinist also owns an injection molding company so I might make the plate out of a phenolic material to help out. Here is the link http://www.highaltitudeimports.com/v...4&referrerid=2


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Check out www.highaltitudeimports.com

[falconGSR]

Wow man I hope you get to build this.

Isin't the SC going to be moved down and interfere with the alternator? Or is there enough room?

<BLOCKQUOTE><font size="1" face="Verdana, Arial">quote:</font><HR> I've seen a similar sized setup on a V8 net over 40 hp at 9psi on a 300 hp motor<HR></BLOCKQUOTE>

Huh? Which V8 needs 9psi of boost to make 300hp?

<BLOCKQUOTE><font size="1" face="Verdana, Arial">quote:</font><HR>The blower itself can safely spin at up to 14,000 rpm. Now with an 8000 rpm redline thats nearly 41 psi of boost, <HR></BLOCKQUOTE>

Huh? Can you explain the math? The pulley multiplies the engines RPM so, at 8000rpm, you're getting close to redlining the blower if you're running more than 12-14psi.


<BLOCKQUOTE><font size="1" face="Verdana, Arial">quote:</font><HR>15-20 psi safely on a daily driver seems like a reasonable goal if the core is efficient enough. <HR></BLOCKQUOTE>

Huh? See above.

I really hope you try this out. Keep us posted.

Joe



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Boost. Finally.

[zip]

Good luck with the project Brian! If it works, I'll be the first individual to buy one.




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Mods

[99SIVTEC]

Thanks man, I hope to have a working prototype on the car by the end of the month.

The Alternator is about the only thing in the way. The injector wires will need to be spliced and lengthened a couple inches, but thats not that big a deal. I'm either going to machine a new bracket for the alternator that moves it down an inch or so, or machine the top bolt out a bit so I can pivot the alternator out of the way slightly. Both methods should not mess with the belt geometry enough to make a difference.

As far as the math for the blower speed. Your boost is commonly measured in a percent of overdrive or underdrive. At 6 psi the civic si kit is 10-11 percent overdriven. you ca then find the blower rpm at redline by taking your cars redline and multiplying it by the percent overdriven. In this case the supercharger is spinning at 8800 rpm's at 8000 rpm of engine speed. You still have plenty of room left to spin the SC faster. This method of calculating mearly figures out the blowers max rpm and doesn't take into account efficiency. Here is a link where we discussed this further.
http://forums.clubsi.com/ubb/Forum12/HTML/007345.html

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Check out www.highaltitudeimports.com

[falconGSR]

Cool man! Looks like I fudged my math too far. Good luck!

Joe


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Boost. Finally.

[99SIVTEC]

haha, its ok man. The first time someone told me the max blower speed my first thought was, damn were almost at that speed already. I finally did the math and was surprised to find how much room we actually have.

Oh and thanks zip for posting the pics up over here

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Check out www.highaltitudeimports.com

[HyBridEX]

PLEASE keep us posted on your before and after testing/results........including DYNO graphs too

GOOD LUCK

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95 Hybrid w/JDM B16

[Peyomp]

w


[This message has been edited by Peyomp (edited September 04, 2001).]

[Peyomp]

Does the Si have that much less space than the GSR? Because when I did all the measurements in my GSR for a similar project, using a custom manifold, there was enough room for a 2.25" spearco air to liquid intercooler core. Or even for two side by side (same thickness but wider).

And how are you connecting the core to the manifold? Brazing? What manifold material are you using?


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[Peyomp]

Okay, now I get it. You're utilizing the stock JR manifold and using a "sandwiche" design. I get it. I never could find a core that would work worth a damn in that ocnfiguration, or clear the alternator. I'm playing around with a straight shot manifold with the core inside and I was thinking along those lines when I read your post so I done got confused.


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