OK, so I'm forging together my own intercooler out of a combination of high quality Hypermax parts (2-1/2" diameter I think), and chinese ebay parts (3" I think). I've got a lot of pipe that is in various pre-bent assortments that is the 3" variety. I'm not really sure yet how it all is going to go together. What I am wondering is, can I go from the smaller Hypermax pipe into the larger ebay stuff into the intercooler (same 3" openings), then out of the intercooler into the 3" and then back to the 2-1/2" stuff. I'm thinking sure, since the volume of air inside the intercooler probably results in a change in volume and velocity anyway, and the air is probably getting compressed a little on its way out of the intercooler. Anybody got a degree (or equivelent experience) in this kind of science that can comment with authority? All comments and speculation welcome just the same.
Intercooler design question
- Thread starter Agnem
- Start date
Dirtleg
Full Access Member
Mel, I wouldn't be too concerned when going from a 2 1/2' pipe to a 3" and then back again. There will be loss of velocity that won't be recovered 100% on the return to the smaller pipe. But it is this way with all intercoolers anyhow. It is the change in air density that is what's important here. Oh and my scientific credentials would put me in the speculation category.
It seems from your post that you are headed down the right path anyway. Again speculation.
It seems from your post that you are headed down the right path anyway. Again speculation.
ghunt
Full Access Member
I don't know the science of it, but I have an IC with 3" inlet/outlet on my Bird and I'm running 2 1/2" intercooler pipes on it.
Most people use reducers on their IC inlet/outlet since 3" is way too big and a pain to run anyway.
Most people use reducers on their IC inlet/outlet since 3" is way too big and a pain to run anyway.
77f250diesel
Full Access Member
Mel...Think of the air as being water flowing through a pipe. If you started with a 3/4" pipe then increased to 1" then back to 3/4 your flow isn't going to change. They'll be a drop in static pressure (resistance to flow) passing through the 1" but then your necking down again on the other end.
On your turbo your pushing hot air through the 2 1/2 which will have a lower static pressure (hot air is less dense) into the 3 then the IC where you get a pressure drop (the smaller the tube the more resistance) then back to 3 then 2 1/2 but now the air is cooler (more dense) so the resistance would rise again but still probably less than the IC.
Man I hope that's not confusing.
I hope that helps, it's been a long time since I was involved in air flow calcs.
Dennis
On your turbo your pushing hot air through the 2 1/2 which will have a lower static pressure (hot air is less dense) into the 3 then the IC where you get a pressure drop (the smaller the tube the more resistance) then back to 3 then 2 1/2 but now the air is cooler (more dense) so the resistance would rise again but still probably less than the IC.
Man I hope that's not confusing.
I hope that helps, it's been a long time since I was involved in air flow calcs.
Dennis
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tractorman86
Registered User
they make 2.5-3" silicone reducers, just more speculation but i'd bet you will never know the difference.
dyoung14
Is getting worn out
an intercooler is something i plan on doing after i get the psd turbo all working right probly use a psd intercooler, mel what intercooler are you using?
typ4
Full Access Member
Mel I think the only time you may notice a difference is around 30 lbs boost and 6500 rpm.
Speculation with experience.
Speculation with experience.
Dsl_Dog_Treat
I lost my face to the jaws of a poodle
At those RPMs and 30psi of boost in one of these old engines I think he would notice a difference in the location of some of the engines vital parts
I was thinking the same thing.OK, well this all sounds along the same lines I was thinking. I need to take the truck for a run and make some somewhat scientific measurments so I can record the hoped for improvement. I will need to get some reducer boots for sure. The intercooler is an ebay one from CRX racing or something like that. It's about 22" X 12" X 3" and came with a bunch of 3" pipe. I'm thinking to myself how the heck your supposed to use this with a Mustang which is what they market it for. Hope to have some pics up over the weekend.
Darrin Tosh
IDI Hound
Sounds like you need the 2 1/2" pipe that I got for Ron, and he needs your 3" pipe,..
Darrin Tosh
IDI Hound
Looks exactly like what I got in the 3"! I'll post pics tonight. If they are what he needs then we can do the swap. No need to overnight. Next weekend will be fast enough. I'll need some time to get the intercooler mounted anyway. Are a couple of those 90's?
Darrin Tosh
IDI Hound
Sounds good I will get them out to you tomorrow, I think I have your address i'll check, or do you want them shipped to your buisness?
