Shots of my Homemade Air-Water Intercooler
01-29-2003, 06:15 PM
#1
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Shots of my Homemade Air-Water Intercooler
Alot of you guys know I am building a low-budget ZC race car, that is hopefully going to be done by spring (yes this year! hah) Its in a million pieces right now, but I thought I might take a few pics of the intercooler setup. I really didn’t want to spend 1000 bucks on the spearco air-water intercooler w/ pump. So I wanted to do my own for a fraction of the price. It may not work as well as the spearco, but I don’t give a ----, if it poses a problem in the future I can always upgrade 
It first starts off with a factory Saab intercooler, its a perfect size, the core is very thick and appears to flow pretty decently. I picked this up for $20 bucks at a local salvage yard.
I then took the intercooler to a friend of mine who does great work with aluminum and welds very nice. He basically welded a complete aluminum box all the way around the cooler. I had him chop the inlet/outlet pipes and rotate them so they would be aiming forward.
Here is a side shot, he had some nice aluminum fittings (1/2 inch) that he welded in for the flow off water, 1 at the top and one at the bottom on both sides. He charged me 75 bucks for everything, which I thought was very fair, I had a few quotes around $100-150ish from other places.
I picked up this inline pump at a boat parts store (boaters world) it flows 3.3gpm and should do just fine. Cost was $75
I still need to get a reservoir tank to hold the water, probably going to get a 1-2 gallon tank. Where am I going to mount this intercooler at? well its going inside the car directly behind the firewall. It seems its going to be the easiest way to do it, since my turbo sits in an odd location.
Pics coming soon of the install....
It first starts off with a factory Saab intercooler, its a perfect size, the core is very thick and appears to flow pretty decently. I picked this up for $20 bucks at a local salvage yard.
I then took the intercooler to a friend of mine who does great work with aluminum and welds very nice. He basically welded a complete aluminum box all the way around the cooler. I had him chop the inlet/outlet pipes and rotate them so they would be aiming forward.
Here is a side shot, he had some nice aluminum fittings (1/2 inch) that he welded in for the flow off water, 1 at the top and one at the bottom on both sides. He charged me 75 bucks for everything, which I thought was very fair, I had a few quotes around $100-150ish from other places.
I picked up this inline pump at a boat parts store (boaters world) it flows 3.3gpm and should do just fine. Cost was $75
I still need to get a reservoir tank to hold the water, probably going to get a 1-2 gallon tank. Where am I going to mount this intercooler at? well its going inside the car directly behind the firewall. It seems its going to be the easiest way to do it, since my turbo sits in an odd location.
Pics coming soon of the install....
01-29-2003, 06:33 PM
#2
3.0 BAR
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Re:Shots of my Homemade Air-Water Intercooler
looks good.
really good.
really good.
01-29-2003, 06:43 PM
#3
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Re:Shots of my Homemade Air-Water Intercooler
says its regulated at 40psi, basically the same thing as the spearco (jabsco) pump.. just flows a bit less gpm.
Jeff
Jeff
01-29-2003, 06:44 PM
#4
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Re:Shots of my Homemade Air-Water Intercooler
yeah i modified my post cause i found out the pump was 120.
but only uses like 3 amps and pumps alotta wata
but only uses like 3 amps and pumps alotta wata
01-29-2003, 07:32 PM
#5
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Re:Shots of my Homemade Air-Water Intercooler
Looks very nice. I wish I knew someone who could weld aluminum that good and cheap.
Make sure you can fit a lot of ice water in the reservoir.
Make sure you can fit a lot of ice water in the reservoir.
01-29-2003, 08:37 PM
#6
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Re:Shots of my Homemade Air-Water Intercooler
looks good Jeff! if you do deside to upgrade that thing will go for tons one ebay! 
01-29-2003, 08:45 PM
#7
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Re:Shots of my Homemade Air-Water Intercooler
Nice!!!!
Thats ------- awsome Jeff! Love your low buck 'solutions'.
Thats ------- awsome Jeff! Love your low buck 'solutions'.
01-29-2003, 11:21 PM
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Re:Shots of my Homemade Air-Water Intercooler
Or I could sell it to beau for 500 
01-30-2003, 12:38 AM
#9
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Re:Shots of my Homemade Air-Water Intercooler
"Or I could sell it to beau for 500"
or i could just charge you storage rent
Beau
or i could just charge you storage rent
Beau
01-30-2003, 12:40 AM
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Re:Shots of my Homemade Air-Water Intercooler
Bah, I am on good graces with grandpa gary 
I am getting a nitted sweater baby.. haha
I am getting a nitted sweater baby.. haha
