Air-to-water intercooler

[JeepSJ]

Anyone have any idea how hot the water gets in one of those systems?

I have space limitations for any type of intercooler setup, but I may have an idea for an air-to-water unit.

Here is what I am thinking - start with the hose that is the return from the heater to the engine. Route that instead to a smaller radiator in front of the grill (same as with a normal A2W setup), then to the IC, then back into the engine.

This would save me from needing to add an extra water tank and pump for the IC circuit. My only concern would be whether or not I could remove enough heat from that water to make effective.

If I knew how hot the water got in a A2W system, that would tell me if this is a valid option. For example, if the water gets to 200 degrees and aux radiator is able to cool it to ambient, then this might be an option.

I think I'll post up on the Ford Lightning forums and see if anyone is monitoring their IC water temps.

Thanks!

[More Power]

Some basic facts... 1- Boosted air in the 6.5 can reach 200+ degrees F or more. Some have reported 250+. 2- The greater the temperature differential between ambient air and the medium you're cooling, the the greater the percent change of temperature drop in the cooled medium. 3- There is about 1 horsepower change for every 10 degrees F change in intake air (cooler adds power, hotter decreases power).

I'd not use engine coolant as a cooling medium in an air/water intercooler. :)

Jim

[KrisL]

try giving vortech superchargers a call they use air-to-water coolers in there setups so they should be able to give you some insight and specs on what your doing. You might even be able to use one of there setups with minimal fab work.

[JeepSJ]

Thanks guys. I was looking at this as an option because I have no extra room for another coolant reservoir or the pump. From a few responses on the Lightning forums it sounds like their water is only getting up to about 125 or so in their reservoir, then it goes through the heat exchanger and then to the intercooler. I may just need to get creative on the mounting location of the tank. I WILL get some type of intercooler into this someday...

[More Power]

www.peninsularengine.com (http://www.peninsularengine.com) had been working on a water/air intercooler (charge air cooler) for the 6.5 on-road applications. This is essentially what they use on their marine 6.5s, but modified to work in a truck.

Cost and somewhat more complicated installations are what has held development back for all manner of water/air coolers. Generally, these are reserved for applications where there isn't space for an adequately sized air/air unit.

We'll have a new DIY air/air charge air cooler article on the web site before long. The low cost (~$400) should make this an attractive option. :)

Jim

[dieselrealtor]

[URL="http://www.peninsularengine.com"]

We'll have a new DIY air/air charge air cooler article on the web site before long. The low cost (~$400) should make this an attractive option. :)

Jim


How soon do you think this article will be ready?

I am thinking of doing this pretty soon.

[More Power]

The article is nearly ready. It'll be a part of the regular monthly updates for this month. :)

Jim

[Slim shady]

Something to think of with a air to water intercooler is the heat retention water has.
Water will absorb heat well when cold but, it also will retain a certain amount of the heat if it can not shed enough of the heat through the exchanger. This is why the marine engines run so much cooler, you have a whole lake to dump heat into.

That is why a hot water heating system works well, water retains the heat and never sheds all of it.

I looked into it before I went with my air to air exchanger, more air out there to dump heat into. The metal exchanger retains heat after running for awhile but it cools relatively fast when the vehicle is on the highway.

The air to water cooler may have an advantage at stop and go city driving. Just my two cents worth, something to think about.

[JeepSJ]

I don't have enough room behind my grill for an air/air unit. The heat exchangers for a water/air unit are thinner and I think I have just enough room to squeeze one in there.