Intercooler upgrade/fix

[kbvagtech]

I decided to take care of my leaking intercoolers. After seeing some of my
options(new stock, aftermarket, or jb weld) I figured Id just make my own.
Picked up some Bell 3"x9"x10" cores and started cutting, fitting, and welding.
Could have went with a 3.5 core, but o well. Still managed to keep the extra
heat exchangers and all the stock ducting.

http://i1034.photobucket.com/albums/a421/kyleb3/fabstuff/20140427_191614.jpg

http://i1034.photobucket.com/albums/a421/kyleb3/fabstuff/20140428_222942.jpg

http://i1034.photobucket.com/albums/a421/kyleb3/fabstuff/20140428_223011.jpg

http://i1034.photobucket.com/albums/a421/kyleb3/fabstuff/20140503_102700.jpg

http://i1034.photobucket.com/albums/a421/kyleb3/fabstuff/20140503_103337.jpg

[4everRS]

Great beads! Really nice work. Thanks for sharing

[Zmey]

You just did what Apikol does and same bell cores, outstanding man.

[Other_Erik]

Correct me if I'm wrong, but I thought our IC's had some sort of secondary water cooler mounted to them? If you're running without those, why not go for a thicker core?

Stock IC's are 9.8x8.1x2.6 core with a secondary 8x8x0.5 (again, if I'm recalling correctly) - you've got an awesome fit/finish going on there, but if you're rolling your own shouldn't you look for something a bit more hefty? Wags are 10x9.2x4", but with a different shroud, and I'm sure you don't want to fab your own there.

Any chance you've got airflow numbers for those bell cores? Stockers are supposed to flow 3331cm^3 according to Wagner-Tuning

[kbvagtech]

Correct me if I'm wrong, but I thought our IC's had some sort of secondary water cooler mounted to them? If you're running without those, why not go for a thicker core?

Stock IC's are 9.8x8.1x2.6 core with a secondary 8x8x0.5 (again, if I'm recalling correctly) - you've got an awesome fit/finish going on there, but if you're rolling your own shouldn't you look for something a bit more hefty? Wags are 10x9.2x4", but with a different shroud, and I'm sure you don't want to fab your own there.

Any chance you've got airflow numbers for those bell cores? Stockers are supposed to flow 3331cm^3 according to Wagner-Tuning


High-performance 255mm x 230mm x 105mm Intercooler Core that flows 6158cm³ air volume vs. OEM 250mm x 205mm x 65mm, 3331cm cubic volume!



I dont believe the numbers on wagners site are flow numbers, looks like it is just the volume that their core displaces. 25.5*23.0*10.5=6158, 25.0*20.5*6.5=3331. So if we are talking numbers like wagner, mine sit at 4424 cubic cm. Bell rates them at 482cfm.
The next size thicker Bell core is 3.5"x9"x10" and is rated at 562cfm.

I did keep the extra "hot climate" heat exchangers, i had thought about removing them, but they weren't leaking and I figured audi put them there for a reason. Plus I figure them plus all the tubing has to hold close to a gallon of coolant, which can only help cool the beast.

[marklar182]

Awesome work! Bell cores are the best, I have 4.5" Bell cores on my 300zx.

[SteveKen]

Very nice work.

[mik15]

that look great man, where can i buy the cores from and how much do they cost?

[marklar182]

that look great man, where can i buy the cores from and how much do they cost?

You can buy directly from Bell Intercoolers.


<tbody>

3.00

9.00

10.00
CFM
482

$247.00
PN#
A300090100

</tbody>

[vtraudt]

Picked up some Bell 3"x9"x10" cores and started cutting, fitting, and welding.
Could have went with a 3.5 core, but o well. Still managed to keep the extra
heat exchangers and all the stock ducting.


With the end tanks coming of stock 2.6" thick cores, how would they fit on a 3.5" thick core?

[vtraudt]

Stock IC's are 9.8x8.1x2.6 core

Just for me to visualize.
Flow is "top to bottom" or in "long" direction

https://drive.google.com/file/d/17go_orrT7Od0yTK3VmmDyCtG8JBb14dh/view?usp=sharing

.

[GreggPDX]

With the end tanks coming of stock 2.6" thick cores, how would they fit on a 3.5" thick core?

I haven't done this myself (yet), but if you look at the pics, you can see that the mounting flange for the stock core is quite a bit wider than the core itself. You can use this space to fit a wider core and weld the new cores flush with the edge of the tanks.

[vtraudt]

I haven't done this myself (yet), but if you look at the pics, you can see that the mounting flange for the stock core is quite a bit wider than the core itself. You can use this space to fit a wider core and weld the new cores flush with the edge of the tanks.
Thx. Need to see it in person (why would mounting flange for stock core be wider than core?).

[nubcake]

There's a ton of pics in 1st post. :)
First one shows dissected stockers, others - welded aftermarkets.
Stock cores have a "skirt" surrounding them, which welds to end tanks (also where it leaks all the time).
Aftermarket cores are usually designed a bit differently.

18642