DS3 Intercooler

[ds3r]

hi chris thanks for that might be a little bit smaller but with the big pipes theres so much flow

[Fabian]

About the pipework.

Think the pipe from the turbo goes down like standard.
Then with an 90 degree bent to an pipe behind the intercooler.
After that with an 180 degree bent to the intercooler
Then exit side Intercooler via the standard pipe back up to the inlet

Above is how it also looks like with my intercooler

[hangar111]

Hi, a few questions to answer here so I'll have a quick bash! :O)

Size of the intercooler is smaller than 'Forge' intercooler
The external dimensions of our prototype are indeed smaller but the overall design is less restrictive. This is partly due to using more rows and partly due to larger pipe diameters. When we build up a Chargecooler or Intercooler system (we have done a few!), we like smooth-flowing air that doesn't get restricted or forced into tight angles where the air would slow down reducing boost and reducing the overall effectiveness of the cooling. We have proven this in practice over the last 5 years in Lotus applications.

An intercooler will by default reduce the boost given by the turbo - e.g. the cooling effect is not "Free" - there is a slight cost. There are some things to bear in mind:
1. A little restriction is needed to ensure that the air spends long enough being cooled!
2. The more restrictive an intercooler or pipework is, the lower the boost will be on the other side.
3. The lower the boost after the intercooler, the more of an impact on engine performance as the ECU will not be happy.

We've seen drops of 2-3psi in some systems which is more than enough to cause the car to run rich at higher RPM. In rolling road testing, intially this may give more power at the top end, but the ECU will soon work out that it is fuelling too much and reduce fuelling to get things back to 'normal'.

In a system where the restriction is kept to a minimum (e.g. 0.5-1psi loss), then the ECU is happy, fuelling is virtually unchanged and the power improvements remain constant.

'Offset' Position (Intercooler not central)
The offset position is essentially to get the best pipe positioning without compromising on the points mentioned above. It's all about the function at the end of the day. If the intercooler was black I doubt this would be a worry. I like the idea of an anodised black or dark grey finish on all components using dark grey silicone hoses.

Pipe Routing
To achieve the best possible unrestricted air flow we chose to route the turbo to intercooler hose under the car in good airflow, leaving a shorter hose back to the engine inlet so there is an absolute minimum risk of the air re-heating between intercooler and engine. Simple flowing pipework with no sudden angles, tight corners or restrictions.

Here's a chargecooler we designed a couple of years back which has been very successful. Video is just after a power run while everything is hot. It may not look much but this little chargecooler keeps everything in a 270bhp Supercharged Elise nice and cool. There are some fancy internals at work here - it's not all about the exterior appearance. :O)

[Chris_Blue]

Good write up Hangar- thought Intercoolers were straightforward. Obviously not
Will see how you go with DS3rs for a bit
Just to clarify- Any " modifications" to car structure needed, other stuff moved? Or straight bolt on
CBLUE

[ds3r]

hi chris none at all bolt intercooler on pipes on job done well not as easy as that but you know what i mean, did a lot of miles this week end testing all good omg just keeps pulling very quick car rolling road soon .

[Chris_Blue]

Some of Czars contributions on Intercoolers suggest that a better airflow with the OEM could have results
I noticed on the DS3 Rally car, that they have taken the fog light out from the intercooler side, and covered with a grille

That made me think that could you take out the foglights (Don't think they are law) and use the intercooler side one, to channel air direct to the OEM intercooler and would it make any difference?
Obviously its not cold air, but it would certainly be more direct flow?

[MadMan0]

Does anyone know if fitting the forge dual pass intercooler has a noticeable effect on the engine coolant temps? just wondering because it sits infront of the rad?

[BeefMasta]

Does anyone know if fitting the forge dual pass intercooler has a noticeable effect on the engine coolant temps? just wondering because it sits infront of the rad?

If I remember correctly it drops it by about half, from around 60C to around 30C.

Have a look through similar threads and you'll be able to confirm though.

[Ragnarok]

If I remember correctly it drops it by about half, from around 60C to around 30C.

Have a look through similar threads and you'll be able to confirm though.

I have it installed and yes it works a lot better and based on some tests it drops from 60C to 30C...
http://www.forgemotorsport.com/conte...oduct=FMINTDS3

[Chris_Blue]

Have a chat with Jamie at SPT- He's got one fitted

[Toxic]

how to fit (Not much room under a DS3 Hood)
Thanks
CBLUE

this any good for you?

http://www.darkmoon.org.uk/DS3/intercooler.pdf

[Ragnarok]

this any good for you?

http://www.darkmoon.org.uk/DS3/intercooler.pdf

Sorry I am f*cked up. I do not have Forge, but Clemens which is exactly same but somewhat cheaper.

[Chris_Blue]

Cant be exactly the Same Rag.....or it would be FORGE ?

[Ragnarok]

Cant be exactly the Same Rag.....or it would be FORGE ?

Sag' was du sagst, aber

http://www.clemens-motorsport.info/e...ts/cmds3thpllk

[Chris_Blue]

Cant see the inlet/outlet on the LHS
Looks very similar tho