DS3 Intercooler

[Chris_Blue]

Are you having a before and after dyno run DS3r?
Pictures showing size and location will be good
Has Greg had the intercooler made?
(Know you will )
CBLUE

[ds3r]

hi we know the bhp will run it next week

[Chris_Blue]

Is that around a 10BHP increase?
CBLUE

[cyclone]

hi we know the bhp will run it next week

Is that around a 10BHP increase?
CBLUE

.....

[Chris_Blue]

Was guessing the increase Cycles............ as DS3r hasnt said
Forge one is between 10-13BHP increase
CBLUE

[ds3r]

well intercooler has been fitted wow the difference really pleased it was a cold day temperature reduced by fifty to sixty c video of this and photos next week of intercooler being installed and it looks great testing it for a period of time now

[Chris_Blue]

Cracking DS3r- glad it went well
Gregs on a promise dependant on cost!
CBLUE

[ds3r]

hi thanks for that all i can say is it will be a lot less than the forge one

[Chris_Blue]

Then I will be a happy Club Member
CBLUE

[hangar111]

After a weekend spent under Adrian's (ds3r) DS3 Racing, we established an excellent layout for our single-pass intercooler development. Initial testing has been very promising with the whole system performing above expectations, but it was a very cold weekend so a little provocation on the rolling road is needed after some spirited driving to build up some heat and get a more real-world test.

Performance improvements were immediately noticable with crisper throttle response, partly due to the lack of restriction in the intercooler and hoses (we are running 63mm pipes versus the original 57mm) and obviously the much lower inlet temps.


With the original dual-pass intercooler removed, it is clear to see why the factory configuration is not ideal. Looking at the exposed surface area and lack of clean air to the original unit, it is no surprise that we recorded 56-65 degrees during rolling road testing in the summer. Worth noting is that the pull fan on the rear of the intercooler showed no signs of ever having been used in the 13,000 miles of use this car has on the clock. When we removed it, the ECU showed no signs of complaint therefore we expect it is either not functional or is considered a non-critical system to the engine management (or "Ballast" as we call it).

Testing will continue for the next few weeks during which any design tweaks will be ironed out ahead of going into production with a ready-to-install kit.


Target price for the complete kit with all necessary pipes, hoses, intercooler and bracketry is going to be around £480+vat. Installation takes around 4hrs due to removal of front bumper (which is surprisingly straightforward but just needs a second pair of hands and some patience!).



Some (slightly naff!) video here showing a very basic test after running the car for around 20 mins to get some heat in:
http://www.hangar111.com/video/ds3-i...-basic-test.qt

[Fabian]

Nice write up and pictures :cool:

What was the intake temp after fitting this intercooler?
My Intercooler gave me 30 degrees lower as stock, with an maximum at 32 degrees after some several tests.
Also with me there were no CEL or what so ever after fitting. Think the standard fan is not working in our Climate

Only thing what I can "complain" to this intercooler as above is that it's not in the middle!
Looks a bit strange!

[ds3r]

hi click on the video to see temperature difference will adjust intercooler to middle as we are still testing anyway glad you like it

[Fabian]

thanks! yes temperature drops are great!
Will folow this topic, so am curious how it looks like when finished :cool:

[ds3r]

ok thanks should not be too long

[Chris_Blue]

Looking good DS3r- looks a little smaller than the FORGE one

Would be interested to see the pipe layout as its single pass

Very interested and cant wait to see the final fit and detail

CBLUE