Man.... They sure are pretty. Nice quality work guy's.![]()
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Metalman Well-Known MemberLifetime Supporter
- Sep 29, 2009
- 7,688
- Ex-Owner (Retired) of a custom metal fab company.
- Ratings:
- +7,960 / 1 / -0
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Mini'mon New Member
First Production Unit Shots
Hi All,
Just took some quick mobile phone pics to show what the new IC's will look like before the fins get coated with radiator paint. It's cool to see the copper before it gets its protective coating.
Also, as you can see, the production units have flat mating surfaces for the foam seal built into the plastic diverter on the bonnet.
-Clint -
That is by far the best R53 IC !
I would get one just for the looks..:cornut: -
It looks really nice. Does the copper really need a protective coating?
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Metalman Well-Known MemberLifetime Supporter
- Sep 29, 2009
- 7,688
- Ex-Owner (Retired) of a custom metal fab company.
- Ratings:
- +7,960 / 1 / -0
Here is one of our copper hoods where we purposely added a patina to give it an aged look.
Here is a countertop with no patina applied, freshly finished, but a week later started to turn brown (which my customer completely understood beforehand).
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Metalman Well-Known MemberLifetime Supporter
- Sep 29, 2009
- 7,688
- Ex-Owner (Retired) of a custom metal fab company.
- Ratings:
- +7,960 / 1 / -0
I believe the IC coating promotes heat transfer and it's probably not available in a clear (not sure about clear in a heat transfer coating). A clear powder coat may only become an insulator which kind of defeats the purpose.
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Mini'mon New Member
The coating applied to the fin and tube sides is a thinner paint than the stuff used on the endtanks and IC front & back This promotes heat transfer and allows the spacing between the cooling fins to stay as open as possible.
Most clearcoats are too thick, so they'd be problematic in production.
The protective coating is a must-have because we have customers that live in colder climates (salty roads in winter) and coastal locations (salt air). Though copper the copper intercooler will be more robust than its OEM aluminum counterpart, we needed to make choices that would assure long life and good looks.
DoS may be be offering a version of the IC later this year with a thermal dispersant. However, the copper transfers heat so much more efficiently than aluminum that it might be an unnecessary change for us.
-Clint -
Mini'mon New Member
Coated Tubes & Fins Pics
More mobile phone pics of what the IC looks like after the coating . . .
-Clint -
Metalman Well-Known MemberLifetime Supporter
- Sep 29, 2009
- 7,688
- Ex-Owner (Retired) of a custom metal fab company.
- Ratings:
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Mmmmmmmm..........
If I squint real hard I can almost picture a IC like this but for the R56. -
KC Jr 54 New Member
Ohhhhh that sure is purty....
At this point, when can we expect ICs to be available for purchase and then shipment ?
And i assume finalized testing will be done and then shared shortly ? (Reaaaally looking forward to the results.) -
Dwight Racing with the GodsLifetime Supporter
Go with the thermal dispersant. It's good for a 1-1.5% increase in charge density. Works on any kind of heat transfer surface. I put it on my Helix FMIC and my intake air temp is now the same as ambient!
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Mini'mon New Member
Good thought . . .
-Clint -
Metalman Well-Known MemberLifetime Supporter
- Sep 29, 2009
- 7,688
- Ex-Owner (Retired) of a custom metal fab company.
- Ratings:
- +7,960 / 1 / -0
Ohhhhhh........
I like what I'm hearing....... -
Drool.... -
Mini'mon New Member
A2A-IC Testing Results!!! (finally!!!!)
Hi All,
The last few days have been a blur. The data is late, but complete. Thanks for your patience.
Images of the collected datalogs posted below. The pressure drop logging was a complete PITA, but worth the hard work. Thanks to much to James Irmiger of Urban MINI + TechShop San Francisco & Matt Richter or MC2 and FES fame for their help!
The Car:
Name: "'Blue", 2002 MINI Cooper S w/
15%SC pulley, RMW Head, Schrick Cam, DDMWorks CAI, Milltek Header, Supersprint Exhaust, DoS Dimsport Tune
Pressure Drop:
As you'll see, we're weaving a tight path around the GP's IC's pressure drop curve. but the GP edges by in the upper RPM ranges by a very minor:
0.03 psi @4000 RPM
0.10 psi @6000 RPM
equal psi drop @ 7000 RPM
It's amazing how close the pressure drop is on all 3 units, despite their differences in design. We needed to get more accurate pressure & vac gauges a few weeks ago just to make the testing worth while and show the tiny differences in psi drop.
Datalogs -- Thunderhill Raceway -- Temps in the mid 60's:
The track is where an really IC shows its worth. DoS shines through here.
The blue line is ambient temperature (sensor in front grille).
The red line is the temp before the intercooler (sensor placed in welded bung in the supercharger horn).
The green line is the temp drop after the intercooler (sensor placed in welded bung in the intake manifold side horn).
The black line is speed (sensor placed on an axle).
Stock IC:
GP IC:
DoS A2A-IC:
I posted pricing info up on the DoS website tonight. ( bitly.com/ghOSSd ) Drop questions to this thread, via PM, or via email. I'm happy to answer them.
Also, one last thanks to all on M/A and that "other" forum who helped & motivated us get our data posted.
-Clint -
Metalman Well-Known MemberLifetime Supporter
- Sep 29, 2009
- 7,688
- Ex-Owner (Retired) of a custom metal fab company.
- Ratings:
- +7,960 / 1 / -0
Nice, looks like a quality piece that works.
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Thanks for the data, but I do not understand the Pressure drop graph across the 3 ICs. I expect the Stock S to have the least pressure loss, yet it has the most.
Please splain it to me!
And impressive temp plots, nice dataset. You've got yourself a better mouse trap right there! -
Mini'mon New Member
A) The internal ruffled design of the fins/baffles/turbulators (whatever you personally prefer to call them) in the stock IC tubes is slightly denser than the GP. This generates more pressure drop by causing more restriction.
--or--
B) The internal ruffled fin design is the same on the stock & GP tubes. There's less pressure drop on the GP because the air is less restricted due to the 2X additional rows.
It's a shocker, I know. Pick whatever theory you like, but the gauges told the tale.
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Pressure Drop:
Well, well............the data has spoken!
I like your theories, the full understanding will come, but it is more important to have reliable data to base those theories on! Obviously, my initial theory/understanding of what is what on the pressure drop was WRONG!
Moving on to the temp graphs:
Um.... the 3rd graph is not really a fair comparison cause somebody did not keep their foot in it! Grrr! I mean you can pretty much give a good educated guess at what the plot would have looked like, but still. You knew I was gonna say something!
Also, does the 3rd graph contain the dispersant coating? I would guess yes, but it is not stated. And what does the 3rd graph look like without the coating?
Lastly, and most importantly, you FAILED FAILED FAILED to point out the most important benefit to track going R53s.... with the DOS IC you do NOT get ever increasing IATS lap after lap as with the stock IC, and maybe even the GP IC (though to a much smaller degree). So, with the DOS IC, an R53 will not lose power lap after lap due to ever increasing IATs. This is an important decision point for R53 owners!
That being said.
Even though I can guess what the 3rd plot should look like, you do not really have the data to prove the above selling point due to the specific run at TH. It could be driver, or traffic, or I dunno, but the 3rd run was not the same as run #1 & 2. I'm just sayin'...
Also, do you have pics of Blue with the 3 ICs mounted right before of after the track runs? Do you use the OEM IC cover? Any special consideration under the hood, with foam, etc. Or just use all OEM for everything except the IC itself?
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