800bhp + DIY Project

[TTE Si]

Yeah but until someone sorts out the Charge cooler bottle neck there is little point going for the bigger turbos.

hopefully there will be something by the time I start looking for turbos

Sure seems so but we are selling many every month so tuners think there still worthy and they had many specs from us inc tte8xx

[Paulm]

So someone is making progress? I wont need turbos until mid year, see what transpires by then

[bam_bam]

So are those coolers 'behind' the radiator!? That cannot be good, ne?

[IanH755]

They're charge coolers, not intercoolers so they don't use air flow to cool but use coolant (water?) instead. The coolant in the charge cooler is then cooled by a small radiator just infront of the main radiator at the bottom.

[Paulm]

good compact design just no fun for tuning

[bam_bam]

Hmmmm, just looking at that diagram, it looks ripe to use Phase Change cooling.

• Step 1 - Beef up OEM aircon package
  Step 2 - Redesign cooling jacket for the cooler
  Step 3 - Route into newly beefed aircon
  Step 4 - ??????
  Step 5 - Profit

At the very least you could use CO2 or the aircon circuit to help lower the temps of the charge cooler water jacket. Bigger isn't always better if you can keep the intake temps sufficiently low, ne? Just increase the cooling capacity of the current solution.

[Paulm]

There are options out already to increase cooling but from what I have read its flow that is stopping cars getting over 800bhp. I know forge are looing at a bigger radiator and reservoir to help cooling but no-one has addressed the flow side of thing that I can find?

[bam_bam]

There are options out already to increase cooling but from what I have read its flow that is stopping cars getting over 800bhp. I know forge are looing at a bigger radiator and reservoir to help cooling but no-one has addressed the flow side of thing that I can find?

Do you mean an engine coolant radiator and reservoir? I was taking about the charge cooler (some call it these intercoolers) having a better efficiency.

Anyways, is flow or cooler volume the issue?

If it's flow, is that the pre-cooler intake flow or the 'flow' from the cooler itself and/or supporting pipework? i.e. where is the bottle neck.
If it's volume then that's an issue, there's just no where extra/larger charge coolers can go. It'll end up being the "radiator in the boot combined with a FMIC a la Quattro Sport S1" style solution.
No doubt someone will figure out the sweet spot of air blocking the radiator in combination with a FMIC.

All summation and bro science, of course.

[IanH755]

Bam - The charge cooling has it's own reservoir and radiator which is separate from the engine coolant res/rad setup. It is these that are being made bigger to help the small charge cooler work more efficiently by getting more coolant through the charger cooler and then cooling it faster by using a much bigger rad.

However, the 900+ hp issue is mainly air flow through the Charge Coolers (restricted pipework diameter/bends is the biggest issue) and also volume, but that's to a lesser extent, although bigger is always better

[Paulm]

thanks Ian, I did not explain myself very well

[GTM Bandit]

Im planning out a swap for my 2009 S5. After all my research at this time, an Air to Air intercooler may be the true answer. If you're planning on keeping that half a shoebox Paul, you should look into water meth.

[GTM Bandit]

[TTE Si]

The sportmile c7 did drop the charge cooler and go air to air.

[bam_bam]

Bam - The charge cooling has it's own reservoir and radiator which is separate from the engine coolant res/rad setup. It is these that are being made bigger to help the small charge cooler work more efficiently by getting more coolant through the charger cooler and then cooling it faster by using a much bigger rad.

Ahhh, got it. So it has its own circuit, that's awesome. So the remit should be to increase the charge cooling circuit output while making the core more free flowing? I see how the pipework is an issue.
Bigger isn't always better with charge coolers, if it's too big you'll tkae an age to make pressure, certainly not a problem here! I'd bet some tuners are just thinking about stuffing a huge single turbo into the V to minimise pipework.

I'm out. I need to sit in front ETKA for this beast, very interesting.

[MartayMcFly]

• Step 4 - ??????
  Step 5 - Profit