"FMIC" front mount intercooler help

[PEN]

okay sooo I get the basics of turbo and everything but what I would like to know is how to make an intercooler and what materials does it need. Lastly hows it specifically work and look like on the internals.

[BLUEMEANIE]

That's an easy Google search man.
http://www.google.com/search?q=how+d...tercooler+work

In short, a turbo compresses air. When you compress air, it gets hot. When air gets hot, it expands. Since expansion means that the engine gets less air than it could. An air-to-air or liquid-to-air intercooler, a big heat exchanger (aka radiator), is used to cool the air temp. You run the hot compressed air from the turbocharger through the intercooler to bring down its temperature and make it more dense.

There's a lot more detailed information via that link I provided.

This is probably the most detailed explination - http://www.gnttype.org/techarea/turbo/intercooler.html


As far as making one from scratch. Just buy one. There are plenty of kits available for the 3sgte and if you boost the 5s you'll need to get a universal FMIC fit and mounted plus the pipe custom fit, cut and joined.

[PEN]

Ohh I see so the compressed air goes through and as it does its sucking in outside colder air as well?


<<<<< =///\\\= <<<<<< the little arrows are air flow from turbo to intake manifold.

^^^^

[BLUEMEANIE]

No, with an air-to-air intercooler the charge air from the turbo flows thru the interior of the cooler itself. The outside air flows around the fins of the cooler, cooling the internal (charge) air. The reason for its large flat shape is so it can maximize cooling surface. Similar to how a radiator functions.
Some setups utilize a CO2 sprayer that literally sprays the front of the metal intercooler with compressed carbon dioxide causing it to briefly freeze and further increase cooling capacity.

A radiator uses air flowing over its surface (fins) to cool water/anti-freeze and maintain engine temp.

A liquid-to-air intercooler uses anti-freeze already cooled by the radiator to cool the charge air.