Laminova water to air intercooler

[awill4x4]

A few people here know of my interest in the fabrication of various intercoolers, well here's my latest. It's a Laminova cored water to air intercooler for a TD42 the pics below show the fabrication including a close up of the core design and construction.
Regards Andrew.












[img][/img]

[mickyd555]

Andrew

I havent ready the thread on outlerlimits, plus i think there are people here who dont get on there.

Can you give me the basic principles on why you use the laminove core, i assume its giving you better results but is that just because of its size or other factors?

[Roachie]

That is a thing of beauty!!! Lets see how it goes.... Should be a real p!sser I reckon.

[awill4x4]

Originally Posted by mickyd555

Andrew
I havent ready the thread on outlerlimits, plus i think there are people here who dont get on there.
Can you give me the basic principles on why you use the laminove core, i assume its giving you better results but is that just because of its size or other factors?

I got involved in these through Matt McInnes also on Outerlimits when he asked me to weld his together. At the start I thought "these are never going to work" but I welded it together for him and then they got me interested, really interested. When you initially look at them your immediate thought is "you can't flow air through those" well take it from me, you can. The next thought is "how can you possibly cool the air when it's only travelling such a short distance around the core?"
It's when you look at the maths of just how large a surface area each core has that you realise it is absolutely massive. Each fin is 0.2mm in thickness and the gap between each one is 0.3mm so there's more air gap than fin so think of it as thousands of razorblades cutting the air as it passes between them and transferring the heat to the water which is then passed out the intercooler to its own heat exchanger.
Very short inlet tract so lag is no longer an issue, compact in design and very efficient, it's a win win situation.
Add to all that it's really freaky stuff that people just don't believe can work but we've proved it can and does.
How does post turbo temps of 82C with post intercooler temps of 32C and a flat line of 5C temp rise above ambient sound? That's what we're getting on Matt's one a 50 degrees C temp drop at 8-9 psi.

[mickyd555]

Originally Posted by awill4x4

How does post turbo temps of 82C with post intercooler temps of 32C and a flat line of 5C temp rise above ambient sound? That's what we're getting on Matt's one a 50 degrees C temp drop at 8-9 psi.

sounds excellent, would more boost give a better colling effect or would that just bring more temperature to start with and a similar drop in temp?

[db1891]

How much to suit TD42 what sort of time delay.
Do you do a radiator for this heat exchanger (Big one) to suit this for a GQ nissan patrol.
Thanks
Darren

[benhl]

take a ticket and get back in line - i've been watching this from the begining on OL and have my hand still firmly UP for the first production model (or at least in the first 5-10) regardless of the wait.

I'm not even bothering looking any further into coolers until these are in production. They are fantastic and simple to integrate into any TD42 system configuration...

[Matt.McInnes]

The install

1st up out with the DTS





In with the the new.

[Matt.McInnes]

The intake and turbo reconnected.

GUTD42 air box with a ZD30 lid, Marin did get a complete ZD30 air box but the bottom half's are the same and the GUTD42 air box was all ready fitted.

[marin]

Who let you on here :P

hopefully radiator is good for when I get back and I/we can install it

marin

[Matt.McInnes]

The heat exchanger/radiator.

Spent the morning at the wreckers looking at al-sorts and ended up going with this late model Telstar.





Feed to the pump.



Trimmed the grill a little but no Chrome was lost





The radiator is currently at TrikFab with the plastic end tanks cut off to be replaced with Ali ones and feed in and out to suit our needs.

The Grill is pretty much intact but for those that don't want to chop a custom one would be easy, though a little shorter better quality and as always make the wallet a little lighter.

[Matt.McInnes]

Ordered a Spal 13" push fan, this will cover half the heat exchanger on the passenger side leaving half for air to flow though freely on the road. It will also blow air through half the air con heat exchanger that is behind it.

Slim-line fan 55mm thick and 1650CFM all this should fit behind the grill without having to chop it out.

You can also see here we have rolled the top edge over on the bottom cross member to accommodate the radiator rather than cutting it out.



There was originally a fan on the air con unit but much thicker than than Spal slim-line unit.

[truckster]

how about keeping an upto date listing on 'extras' and their costs to see how much this will work out to be.

EG, how much has this setup cost so far on the Red GQ listed?
cooler, cores, fan, welding, pipes, heat exchanger/radiator etc

Lots of people are interested, but I think the total final price may shatter a lot of dreamers.

[Matt.McInnes]

Originally Posted by truckster

how about keeping an upto date listing on 'extras' and their costs to see how much this will work out to be.

EG, how much has this setup cost so far on the Red GQ listed?
cooler, cores, fan, welding, pipes, heat exchanger/radiator etc

Lots of people are interested, but I think the total final price may shatter a lot of dreamers.

Do you want the bling and integrated like Marin or the generic bolt on?

Things like the speed flow 45 and 90 degree fittings are $40 each, stainless braided $30 a meter the piping to look bling can add up real fast over hose tails and hose clamps. But we can do it in either.

Once Awill4x4 is back from his xmas hol's well will be fabricating the generic bolt on version which will be costed.

The Telstar rad was $60 from the wreckers.
Fan was $200 but again you can hit the wreckers and eBay the Telstar had a pair on it but we did not get them with the rad, rather a slim line so not to cut the grill.
Cores are available at present on eBay buy now price $50ea US, new $212ea Aus from Laminova.
Davies Craig pump EWP80 $200

These are not a cheap intercooler by any means but you pay for what you get.

You get to save on figuring out what rad to use and how to fit it. As we have done all the hard work there too for free.

[Matt.McInnes]

Just to give you some idea of what bling adds.

This will set you back around $200



This will set you back under $100



Not including hose and I beat I can buy a whole roll of hose for the price of a meter of Stainless braided.

I hate to imagine the cost of extras for this one and it will be VERY bling. Twin turbo LS1

[Matt.McInnes]

End tanks done and a quick check for size.

Just the inlets and out lets and mountings to do.

[marin]

Radiator is lookin' good!

Truckster, I would prefer not to see the current total cost of mine, best to just keep forking out money in smaller amounts that seem manageable lol easier to justify to myself.

marin

[Matt.McInnes]

Marin's rad will be ready tomorrow, the mountings, bleed point and returns from the intercooler are done. Just the main feed to the pump to do.

Rather than use a 4 way splitter on the return we elected to feed each intercooler core out let into the radiator direct, just need drilling and tapping to take the fittings.

[money_killer]

cant wait to see some results

[mickyd555]

are these for sale yet and do you have any figures to back them up?