Started with a cheap intercooler from one of the suppliers on the web. After scouring through many webpages and ebay auctions for a low cost unit that would fit reasonably well, I decided on the Type 16. It measures 9.5 x 11 x 3.5, and has a thru design on the in and out.
The pump is an SVT replacement that was also pretty low cost, found on the web.
The radiator is on the way, and is off a particular old motorcycle, and has dimensions perfect for the way I want to mount it. It measures about 17x7, which should let me lay it down in front of the radiator, out of the way, fans blowing down
A new heat exchanger is pretty low cost, but I couldn't find a size that fit what I needed, so I set out to get dimensions and choose a used radiator from a bike. I initially thought of installing two smaller dirt bike radiators behind each fog light opening in the air dam, but decided to go for a single, central location, and do the two smaller one as extra cooling if I decide I need it later on.
The ICV and bypass valve was the only real creative part I needed to worry about. Initially, I got two aluminum bungs that I thought I would have welded into the intercooler, and thread in some hose barbs to attach the two tubes. Well it turned out that the intercooler has mounting bosses in the right locations, so drilling and tapping those with the 1/2 NPT drill and tap I had from the turbo install would be easier and cheaper than getting a weld job. When all was said and done, there was enough room between the intercooler and the throttle body to have a pipe welded up with two tube outlets, just like the TCD charge pipe.
The ICV/BPV interface pipe was welded from stainless 2.5" pipe, and expanded to 2.75" on one end to fit the silicone coupler I found locally. The expanded end on the other side was cut off, and this pipe was made as short as possible. I found an s-shaped hose at the local auto parts store, and used this to attach the BPV. Not sure how the little hose is going to do under pressure. The TCD pipe uses silicone hoses, and as much metal tube to bridge the distance as possible. Any guesses??
Finally, instead of cutting up the nice TCD charge pipe, I also got a piece of stainless pipe that was U-shaped with a small radius, and cut that down to attach the inlet of the intercooler down to the turbo.
Before:
Next step will be cleaning up the motorcycle radiator, fitting it down in front of main radiator, and making some mounting down there. Radiator should be here tuesday!
I think I have heat exchanger envy. Did Freud write about that?
