Part of our brief from Terry was that he
wanted it as original appearing as possible. We could only give the
engine cover a minor trim. This limited the size of the ic. unit & so
the amount of charge air cooling that we could give. Computer modeling
came up with a 21kw. heat reduction which means that inlet temps under
full power would drop from mid 90's°c down too mid 50's°c, best case
scenario. This job was given too us through Mercury Motorsport, who were
doing the work on the car, & when they advised Terry he gave us the go
ahead, even though we advised a front mount would give an extra 20°c
cooling at speed, be cheaper by a noticeable amount, but need major
pipework & cutting of the front bar. He doesn't want the car cut up, &
is also going to replace our blue silicon hoses with black hose.
It actually pulled out 22 kw of heat,
allowing Ron to crank in a little more timing & lean the mixture a
little, giving a gain of 38rwhp with the added bonus of a safer tune.
Terry is very happy with the results. It holds the temps to mid 40's°c
for over 15 seconds & the the temp. starts rising slowly up to a highest
of 57°c on an extended power run.
Everything is so tight a fit, we have not
made any jigs as it has to be made to the car. If we made the unit
smaller so it could be home fitted, the performance gain really would
not be worth the money.
This is the room we finished up having
available after we milled the adapter block down as much as we
could (had to weld) & still leave it in place. It really needed to
shorten the intake pipe & remove the EGR ? valve block completely so we
could've made a bigger ic, but that was chopping too much, & would,ve
had to be removed to add oil. We came up with good enough result to meet
the customers aims anyway.
This is how much we machined the EGR block
down. We had to make this retaining strap up as the silicon joiner is
The radiator could be mistaken for the air
conditioning condenser, certainly not the case with a front mount
intercooler. This radiator is 32mm thick whereas a front mount
intercooler would have to be 91mm thick & much more in your face.
The radiator & our timed delay two speed
pump controller have a plastic cover that keeps them all out of sight.
This is the radiator outlet & back of the
The dyno graph shows that before we fitted
the air-water intercooler, the engine made 251.6rwkw (337hp) &
afterwards, 279.8rwkw (375hp). This is a gain of 28.2rwkw (37.8 rwhp) or
This is the smallest power gain any of our units has made, BUT, to put
this into perspective, we had little room to work with & it is a total
minimal size for the job asked of it. Ron spent hours fine tuning for
the 251kw, whereas the 280kw was a completely safe, North Queensland
summer tune, & believe me, there is a power loss (but a customer gain)
The intercooler removed 22kw of heat out of the 860 cfm of 100°c charge
air for a 28 kw gain in power - check the size of the intercooler again
& you'll see why I'm happy with it.