Most liked posts in thread: New R53 A2A Intercooler from DoS

Very interesting and I'm glad to see someone working on solutions for the IC in the stock location. One question I have is that in reading about copper and aluminum it was noted in some of the literature that while copper does conduct heat better than aluminum, aluminum dissipates heat faster/better. I was reading about the materials for making heat sinks and in some of those applications folks would use copper as a base with the fins made of aluminum... Not trying to start anything at all, I'm excited about the prospects of your IC and wondered if you had found that to be true?

Nice work!

PS: Love to test one for you at an upcoming HPDE!

 

how are the plastic endtanks connected to the core? the stock IC on the '05+ Subaru Legacy GT and '08+ WRX use plastic end-tanks and they're known to 'pop off'. here's a pic to show you that you guys are in good company (Subaru's are known for efficient TMIC designs with positive pressure from the hood scoop across the core)

 

Never mind if it works--my god that thing looks nice!

I never thought I could get slightly aroused by an IC, but if that thing works as good as it looks, I might be in trouble....

Do you have direct comparisons to the GP intercooler--ie how do the temps at cruise and under full load under the same conditions compare to the GP IC, and how is recovery compared to the GP IC?

Does this one use a air diverter like the GP IC, and does that projected price include all the parts and hardware? The DoS IC is not cheap; you can get the entire GP setup for at least couple hundred bucks less than that, but if it significantly outperforms the GP intercooler, it deserves a look.

 

You should see it in person! Had it at MITM, but kinda on the down low.

Nice work Clint.

Bryan

 

Hay Clint!

Congrats on getting this one out! Good job...

Matt

 

Thanks for the answers!

 

Thanks! Eventually, I want to swap out the intercooler, and I was pretty much set for the GP IC, but at this point the DoS IC is looking even better.

 

I saw this beauty at MITM and it's, well, "outstanding".

What else can I say

Mark

 

Waiting for more testing against the GP unit. You've got my attention.

 

When I tested a GP...

I measured the same thing... It was interesting to me, but I didn't know if it was unit to unit variations or something in the internal flow.... Anyway, it's good to know that I wasn't crazy....

I did a thread on that over on NAM.... I'll see if I can find it...

Matt

 

So, in rough numbers, and I realize your testing is complete, please share some pressure drop numbers starting with the standard S IC as the baseline.
Max Boost Measurement
Standard S = 15psi
GP IC = ?
DOS = ?
From what you have stated above I would expect the GP IC to be lower than 15psi, and the DOS unit to actually be higher.

And great development work here, thanks for not forgetting about us 1st Gen guys. On my '06 JCW car my IATs are 30F plus Ta for the street and 60+ on the track and climbing each lap. Do you have some track data to share? Do the IATs continue to rise lap after lap as with the stock IC?

 

It is great to see a new IC coming on line.
However, since you clearly designed this, rather than took something off the shelf, why not angle the chambers forward -- to 45deg would be ideal -- so as to allow for a better air flow from the scoop to the rear of the engine bay and exit down past the header? I provided drawings of this some years ago, and posted them on NAM and my website. I even tried to contact some IC core manufacturers, but there was not interest.
I suspect you could improve the performance of your copper IC (and I like the plastic end tanks very much) with better airflow of the cooling air, while still maintaining good air flow of the charge air to the intake manifold.

Good luck!

 

I don't know that it would be that much of a winner

remember the turbulators on the fins create a bunch of pressure drop, so that the flow through them isn't the same as running air through louvers. The reason that non of the IC companies would touch this one is that it would require a whole different way of tooling up to produce the core for what would be an uncertain benefit.

An easier way to achive the same effect would be to have baffles that would re-direct the air into the core, kind of like the two or three fins that are on most diverters.

Anyway, I'm glad Clint took the time to do some really bitchen' end tanks, and to make smooth flow into the core for the intake air. This is where a ton of aftermarket ICs drop the ball and create a performance deficit that takes a bunch of other work to overcome.

Also, a note on testing ICs and how to measure what they do. Looking at just boost numbers is misleading. You have to look at CFM @ a given air temp through them and then look at the pressure drop. Reason I say this is that the cooling of the IC when run in anger reduces air volume and therefor peak boost, even though it may be delivering a denser charge. The way I got around this in testing was to look at pressure drop vs RPM at no load (cause of the limitations of the testing equipment that I had). I ended up with graphs like this:



BTW, I did my TE measurements at redline in 2nd gear from power runs where the car was well conditioned before the run. Even 30 seconds of idling before a run will skew the numbers.

Matt

ps, this is old data, and the "flow through" was a prototype of the Alta flow through. The Alta TMIC was one with very high turbulator density. They changed the design a bit over the life of the product. And the DFIC was a v1. M7 eventually changed the design to lower pressure drop as well.

 

Nice dataset Dr O, thanks for sharing that. This seems to be a nicely controlled experiment. It is definitely not simple to keep all of the other variable constant and ensure you are only varying the IC design.

 

That chart

was taken with the car at rest, holding revs for each datapoint until stable.

For power runs, I'd take the car onto a freeway loop, hold the car at 60 in 5th gear for about 7 miles, then come to a stop and do the power run with less than 15 seconds of rest time. If it was more than 30 seconds, the heat soaking would skew the TE numbers. To characterize 6 different set ups took about 50 power runs.

Good testing is a real bitcch. There is no two ways about it.

Matt

 

You frickin mofos.

I just finished swearing I was DONE with mods. Mofos.

Cause that IC is AWESEOME.

 

They make an even faster recovering red version too, but it costs twice as much....