High Flow Intercoolers
Transcription
High Flow Intercoolers
December 2012 RISTMAS H C Y R R E M Volume 1, Issue 4 PRODUCT REVIEW SPECIAL High Flow Intercoolers G guy Motors in conjunction with Cross Country 4x4 has launched in NZ an exclusive range of race -proven high-performance Intercooler kits for delivering huge power increases while being bulletproof reliable too. The Intercooler kit quality manufactured by Cross Country 4x4 has been recognised as industry leading in Australia. We chose Intercooler kits manufactured by Cross Country 4x4 on top of PWR cores because, like us they have had a great deal of off-road racing experience and have tested their kits against their competitors in the harshest of environments without a single failure. That is why we are so confident in offering these Intercooler kits to our customers. Be assured these Intercooler kits have been put through their paces, tested on and off-road by 4x4 enthusiasts. In fact, in this special Newsletter we go through the results of our own testing based on a Top Mounted Intercooler kit fitted to our demo-truck. “We were so impressed with built quality of the kit we tested the power increase using a dynamometer to measure the maximum power before and after the kit was fitted” Volume 1, Issue 4 Page 2 Basic product review facts: Test vehicle: 1993 Nissan 4.2 Safari GQ Factory Turbo Test scope: Intercooler; Turbo boost; Fuel pump Test equipment: Dynamometer & Grant’s experience! In a nutshell, we use the Dynamometer to record the power output before and after fitting the Cross Country 4x4 Intercooler kit designed for the Nissan GQ Safari/Patrol. Throughout the test Grant and his team looked at factors such as kit built quality, ease of fitting and performance in coming up with their view of the product and its value for money. Before we get into the details from our product test, a little more about the product features and background. These kits come as a standalone Front Mounted Intercooler (FMIC) kit or a Top Mounted Intercooler (TMIC) kit with the following features: An ultra-high quality custom-built PWR Core (PWR custom-make cores for these kits!) Kits designed to run quality stainless pipes where they will avoid damage Custom fabricated high flow tanks from quality 3mm sheet aluminum Manufactured in close ing Pulsed TIG welding Crafted 2.5" stainless mandrel bent piping Kits come with complex pipe work, easy to fit and with the least amount of joins tolerance jigs us- These Intercooler kits have fast grown in popularity and are now the leading Intercooler in the Australian 4x4 market. Cross Country 4x4 Intercooler Kits – What’s the big difference? First Designed by 4x4 enthusiasts, tested by 4x4 enthusiasts and backed 100% by 4x4 enthusiasts. The Intercooler kits come in a large range of models, designed specifically to maximise the best power curve for each vehicle. Cross Country 4x4 has achieved this by putting in countless hours of R&D work so they outperform other similar coolers for cost effectiveness, performance and durability. G Guy Motors can fit these kits, or they can be supplied as a DIY kit with everything you require to fit a cooler system included, designed with installation ease in mind. of all you need to decide if a top mount cooler (TMIC) will best suit your needs, or whether a front mount cooler (FMIC) will do the trick. Generic coolers are often promoted as capable of working with all types of vehicles, but that is just not the case. Cross Country 4x4 custom design and make their kits to optimise the power curve for your vehicle type and use. These kits are built on top of tailor-made PWR cores and not off the shelf units, custom cores that are extremely strong while maintaining a high flow to heat dissipation ratio. Recognised as some of the best cores in the market and proven time and time again on the race-track these give the kits a solid performance guarantee. Traps for the inexperienced exist, with many Chinese imported coolers found to underperform. 4X4 Driver’s Newsletter Page 3 With a tendency to heat soak (not being able to disburse the heat evenly with ample air flow because the cooler is at saturation point) and consisting of very fragile fins – these cheap copies result in an expensive lesson for the few bits of flimsy alloy piping you get! rounded leading edge tube design throughout the manufacturing process. These tubes have an integrated internal fin with a straight-through design, which improves heat transfer for less pressure drop, resulting in higher flow and reduced lag time. Cross Country 4x4 fabricate custom high flow tanks from quality 3mm sheet aluminum. These tanks are CNC folded and pulse Tig welded - inside and out - to ensure durability and high flow. Manufactured in close tolerance jigs and fabricated from smooth alloy plate the inside finish is flawless making these superior in the market. Low restriction internal turbulators Leading edge tube wall thickness for strength Light weight Race and street proven performance Hi-tech “Auto CAD” design Cross Country 4x4 complete front-mount kits come with 2.5" stainless mandrel bent piping designed to fit the best place to run to avoid damage - outside the engine bay is a harsh environment on any 4x4. The 2.5" mandrel bent piping is used so diesels receive the good flow they need to perform, this is particularly important with longer pipe-runs for Front Mounted Intercooler kits. Another design feature is the kits’ pipe work custom-designed to fit easily with the least amount of joins to limit the number of silicon joiners that can deteriorate with the presence of oil and fuel. Everything you require to fit these kits is included, from proper mounting systems to clamps, hoses, nuts and bolts etc. The whole lot is included. Placing PWR Performance Products at the heart of the kits is a smart move because these guys have a strong reputation in the industry – having developed several of the most efficient intercoolers in the world! PWR use a seamless PWR intercoolers are individually hand manufactured with the following features: What an intercooler does for a Turbo? A turbo compresses the intake charge of air to a higher atmospheric level. A byproduct of this compression of the intake charge is heat, and it has to be displaced. The best way of displacing this heat on an engine is an intercooler system. Basically, an intercooler is a heat exchanger. It exchanges thermal energy from one source to another and simply displaces heat. There are a few reasons why this heat is undesirable, but the main issue we will look at is performance and reliability of your engine as well as economy. As hot air is less dense than cold air, the amount of fuel you can atomise into hot air is considerably less than it would be if the air was cold (dense). For obvious reasons the amount of fuel/air mix entering your engine has a fair bit to do with performance of your engine. More fuel and air equals more power. The more power you gain and the more efficiently your engine is running means the less you squeeze the throttle to do the same amount of work. This simply means increased economy. That is why you have Volume 1, Issue 4 Page 4 a turbo fitted, to supply your engine with more air, for more power. However, if the intake charge of air is not cooled down before it enters the engine, you will not be gaining the full benefits of your forced induction setup. Typically intake temperatures on a turbo vehicle that is running conservative boost (less than 1 bar) will skyrocket over 100 deg C. A general rule of thumb is about 8 deg C will equal 1 horse power. This explains in basic terms why you need to eliminate intake temperatures, and why you need an intercooler. Air to air coolers use a fresh supply of air to flow around the tubes of the cooler containing the compressed and heated intake air, thus removing or displacing heat. These have been the main stay as the popular choice in the performance racing industry for decades, as well as OEM manufacturers. You can divide these types of coolers into two categories: Front Mount Intercoolers (FMIC) and Top Mount Intercoolers (TMIC). Front Mount Intercoolers (FMIC) A front mount cooler is the most popular type of system employed today. A large cooler sits at the front of the vehicle for excellent air flow and pipe work leads back into the engine bay. It’s a hard setup to beat for optimal cooling of the intake charge while the vehicle is in motion. That is why it is employed so much in race vehicles that are constantly undergoing speed and endurance. With air flowing over the cooler at the rate the vehicle is travelling, it’s not hard to see why these are so effective. Many car manufacturers currently employ this type of system because of its effectiveness, so a lot of people will upgrade their standard FMIC for a higher flowing unit and release the full potential of their engine. The drawbacks of such a system are the amount of pipe work you have to put into your intake system to plumb the whole thing up. A front mount intercooler requires at least 2 meters of piping fitted to the intake side of your engine and this will without a doubt cause throttle lag. Therefore, a good quality kit will have large enough pipe work, with the least amount of joiners. Another drawback with FMIC systems is they can have a tendency to put extra load on your vehicles cooling system, a quality FMIC system should also be designed so that no overheating issues will occur. The other drawback to the FMIC system is airflow and this is of primary concern to the 4X4 segment. FMIC systems rely on a steady stream of fresh air coming from the front of the vehicle to cool them down. This is fine as long as you are moving at a reasonable speed, let’s say anything over 50km/h. For a good number of off road enthusiasts, that speed may be a little excessive. Likewise, the position of the FMIC poses the risk of damage due to impact, so pipe work may be routed in protected positions to avoid damage or constructed from strong materials. Another problem that has been seen many times is the front-mount cooler being totally blocked with mud. This renders the cooler totally useless. Top Mount Intercoolers (TMIC) As the name suggests, these intercoolers are mounted on top of the engine. The intercooler is fed a supply of fresh air by a scoop in the 4X4 Driver’s Newsletter bonnet. They have none of the issues associated with lengthy pipe work (such as throttle lag) because they can be mounted directly in line with the intake system, from turbo to intake. TMIC systems are free from damage because of the position of the mounting. There is no extra thermal load placed on an engine’s cooling system, and there is little chance of the pipe work becoming blocked with mud. TMIC systems are a popular choice for many car manufacturers because they can see the benefits of their simplicity and performance of this type of system. There are hardly any joining sections to fail, and they are mounted welland-truly out of harm’s way. Page 5 You have true cooling capacity at crawling speeds, instant throttle response because of minimal pipe work, and best of all it doesn’t recirculate its cooling medium. It’s getting fresh ambient air the whole time. In Summary If you’re a hard 4X4 nut who loves pushing the limit of your truck, then a quality fan assisted top mount is the only way to go. It has just too many benefits. If you’re into some off-roading but do a fair amount of highway driving then a quality front mount maybe your answer. Product Testing One downfall of the TMIC system is that they too require a steady flow of air to keep them operating efficiently. This is done in the same way as a FMIC with the vehicle speed being a factor in the amount of air flow the cooler receives. Some OEM manufacturers have overcome this problem by the use of a fan on the underside of the cooler to maintain a steady flow of air, even at zero vehicle speed. Without a decent fan to pull a constant flow of air through the cooler, TMIC systems can suffer severe heat soak, caused by the heat of the engine. A FMIC will still suffer heat soak from radiated heat from the radiator at zero speeds, but not as much as a TMIC due to the fact that heat rises. With a good fan-assisted top mount, you have a cooler system that is hard to beat in the world of off road 4X4ing. With a Quality TMIC system that has been designed with a good fan (say at least 1000cfm) you would have the best off-road cooler combination. It's got all the benefits of a FMIC, without the downfalls. Product Test: Fitting the Kit Impressive as the Intercooler kit is we at G Guy Motors don’t add a product to our range without having confidence in its ability to perform. The Intercooler was put through its paces on our demo truck and this is what the team had to say. The kit was fitted to a TD42T engine was a great quality product and fitted straight to the engine without any dramas. All brackets on the cooler aligned to engine as expected and the fabrication of the cooler itself was top spec. The fact we were able to install the first kit of this brand within the recommended time is evidence of its quality design and manufacturing. Volume 1, Issue 4 Page 6 Product Test: Driving Experience Product Test: Dyno Test Chart Testing the performance improvement of the Intercooler began with a test-drive to the dyno testing facility in Petone. On the drive out the power and torque improvement was obvious with engine power coming on a lot earlier and stronger. Fine-tuning the engine to make the most of the Intercooler’s capabilities while on the dyno gave the best results – 17% INCREASE in torque and 15% INCREASE in Power that comes on smoothly across the rev range! Using this extra power off-road, towing or just when driving on the open road has made a huge difference to the driving enjoyment – gone is the sluggish off-idle response. The Intercooler has kept the engine temperature noticeably down during hard-revving and given more flexibility to the way I drive as I can rely on a steady acceleration curve, springing forward on hitting the power sweet-spot. I haven’t noticed any significant loss in fuel economy with everyday driving – although I am now finding I’m using the vehicle more often as my preferred choice of transport! Grant’s 4X4 Driver’s Club For more information on the Intercooler kit and other top quality 4WD products visit our website www.gguymotors.co.nz and join our 4x4 Driver’s Club to receive product information. G Guy Motors features selective bargains on our Website and Newsletter from our range of ARB 4X4 accessories and our range 4x4 tyres and rims. 4X4 Driver’s Newsletter Page 7 WOF Reminder Service Popular G. Guy Motors has a professional workshop for servicing 4WD and non-4WD vehicles. We are mta Assured so whether you have a specialist 4WD or a family sedan you can expect a quality service and great customer care. Many of our customers have started using our reminder service where we send a letter or email you at the relevant time to remind you of a due WOF or maintenance for your vehicle (4WD or family car). Please give us a call if you would like this reminder service and we will load it into our computerised system—taking the hassle away for you. 4x4 Racing for 2013 “Please remember, we don't just service 4WD vehicles - bring in your family car too for our full service treatment” Grant and his team have been busy working on fitting a full race-proven suspension to his G Guy Motors 4x4 Racer in time for the 2013 race season — it features a huge length extension in suspension travel along with custom built mounts for the new coils and shocks. Grant’s goal is to have it ready for the next Woodville 100 and later race in the Taupo 1000! We’ll share with you the build-up, bringing to “For more details about these offroad racing events please see Grant’s website (see the Events Page)” you insights and challenges overcome as Grant and the team set-about developing his new racetoughened vehicle. New Facebook for G Guy Motors We’ve launched ourselves onto the social network scene with our own Facebook page to share: ARB product reviews; Interesting stories about what’s happening in the 4x4 scene; Examples of our work fitting products to customer vehicles; Notices of sales or Workshop Open Days; Encourage our customers to give us feedback. And we will continue to listen to what our customers want us to share with them. What’s coming up in the next issue Next Newsletter topics include: Our newsletter is available from our website and by clicking on “Join” you will be placed on our mailing list More ARB Product Bargains More on 4x4 Touring 4WDs WWW.GGUYMOTORS.CO.NZ More on 4x4 Trade 4WDs More on 4x4 Racing 4WDs 41 Old Hutt Road Thorndon, Wellington Phone (04) 472 2020 Email [email protected] Disclaimer The information provided in this newsletter is for general knowledge purposes only. G Guy Motors recommends the reader approaches their local 4WD club to gain experience with 4X4 vehicles and the correct use of recovery gear. G Guy Motors accepts no liability for injury, damage or expense sustained as a result of application or mis-interpretation of information provided in this publication.