SE Intercooler upgrade discussion

[Okibi]

With Perth's hot temperatures i've started considering upgrading the SE's intercooler.

I'd ultimately like to build my own system similar to Track Dog Racing http://trackdogracing.com/intercoolerkits.aspx as Gary at Track Dog thinks the MSM would require "complete new instructions and product development." It's on my to do list when I have more time and i've learnt to weld.

Corksport has a cheapish ($400) intercooler plus intake pipes but shipping adds another $280.

The easy solution is to chop the stock pipes to fit an ebay intercooler.

Some initial reading about DIY aftermarket intercooler options:
http://www.mazda-speed.com/forum2/index.php/topic,25097.0.html
(really great write up with loads of photos)
More reading ..
http://mx5cartalk.com/forum/viewtopic.php?f=81&t=52814
http://mx5cartalk.com/forum/viewtopic.php?f=81&t=51417
http://mx5cartalk.com/forum/viewtopic.php?f=81&t=46402
http://www.mazda-speed.com/forum2/index.php/topic,26251.0.html
http://www.mazda-speed.com/forum2/index.php/topic,24586.0.html

I'd rather hide as much of the end tanks as I can, the prime size in mm 700X180X65 or inches 28x7x2.5

Bar plate
http://www.ebay.com.au/itm/Turbo-Intercooler-FMIC-700X180X65-Integra-Civic-Crx-Si-/400210453784?pt=AU_Car_Parts_Accessories&hash=item5d2e66e518
Compress Air Flow Rate <500Cubic Feet/Min, Rated to200-300 Max HP
Pressure Drop 2~5psi@35psi; 0.2~0.5psi@15psi

Tube and fin
http://www.ebay.com.au/itm/2-5-inlet-outlet-Tube-Fin-FMIC-28x7x2-5-Intercooler-/180686223692?pt=Motors_Car_Truck_Parts_Accessories&hash=item2a11bcf94c
Compress Air Flow Rate:<600Cubic Feet/Min, Rated to 300-400 Max HP
Pressure Drop:2~5psi@35psi; 0.2~0.5psi@15psi

Will also need two 2.5"-2.25" reducers and a few MSM guys have also spent time making up baffles to force air though the intercooler/radiator.

Now my understanding is that bar and plate is more efficient and tube and fin will allow more air to flow onto the condenser and radiator.

With the above 2 examples the tube and fin also has a better flow rate so that's my preference but i'm very happy to read others opinions and take their advice onboard.

[geofiz]

I will be using an intercooler from an xr6 turbo. Cheap and easy to find.

[Okibi]

Neither pipe is where i'd want it for an easy fit for the SE, it'd be worth spending more money than stuffing around trying to make one of these work.

[geofiz]

I think the FG version is cross flow with inlet/outlets pointing the right way

xr6_fg_intercooler_big.jpg

[james_p93]

just bourght one on ebay for 185 including shipping. purely reading this it gave me confidence haha thanks!
James

[Okibi]

Any tips on fitting that the Mazda-speed guide didn't include?

[james_p93]

waiting on it to be delivered, still looking at how to get new piping for less boost loss. will be installing it within the week though. ill keep u posted!
James

[NitroDann]

Why not run the stock piping?

its perfect.

Dann

[Lokiel]

Any tips on fitting that the Mazda-speed guide didn't include?

Don't simply use a hacksaw to do it - takes ages. That's what I did when I did mine, leaving everything mounted on the car, and needed to clean the cuts with a file which took forever.

This was my first mod so I wasn't too keen to "go at it" with a reciprocating saw and Dremel - now I'd definitely use them as much as possible. As far as first-mods go, this is an all-or-nothing mod, once you start cutting your intercooler pipes, there's no turning back.

WARNING: The hose clamps are glued on with "super-duper-strength rhinoceros snot" and are very difficult to get off. You'll need to use pliers and something to wedge between the hose and clamp to get them off. I only removed the outer two clamps, the inner two are still connected to the hoses on the intercooler ends and sit up in my garage rafters today.

Take lots of pictures along the way too, many of us will be interested to see how this turns out since you're using a different intercooler (most, including myself, use the eBay Cooling-Pro intercooler which just involves bending a few hard-lines for additional clearance).

[Okibi]

...most, including myself, use the eBay Cooling-Pro intercooler...

Was that bar and plate or tube and fin?

[james_p93]

Why not run the stock piping?

its perfect.

Dann

stock piping has alot of pressure loss ( so i have been told, i dont actully know). would u dissagree? i havent seen to many ppl talking about that topic.


James

[NitroDann]

Turn the boost up?

Its 1-7/8", Ive seen 2" make over 400rwhp on a stock internals RB25.

Why would you get boost loss apart from size, its just a pipe.

Dann

[james_p93]

Turn the boost up?

Its 1-7/8", Ive seen 2" make over 400rwhp on a stock internals RB25.

Why would you get boost loss apart from size, its just a pipe.

Dann

ok sorry :/ wasnt tyring to argue

[NitroDann]

Nah Im not either, hit me with your ideas.

I like the SE piping because its JUST big enough for most people and is routed great and already done, so no extra work.

I havnt yet seen any evidence that it is poor for power but Id like to see it, never hurts to learn or discuss ideas.

Dann

[james_p93]

Nah Im not either, hit me with your ideas.

I like the SE piping because its JUST big enough for most people and is routed great and already done, so no extra work.

I havnt yet seen any evidence that it is poor for power but Id like to see it, never hurts to learn or discuss ideas.

Dann

ah k i see, yea also havent seen any proof.. just what ppl think :p glad to hear the cheap option is the exact same. cheers !

James