SMICs yield 30+WHP!

[silva]

As some of you already know, I had some custom side mount intercoolers manufactured to my specs.

These have 8"x8"x3.5" cores, and were made to fit the OEM locations without any modifications whatsoever.

Monday of last week we set up a dyno day at four-star motorsports in Georgetown, Ontario, and I did three runs in the morning, with the stock intercoolers in place.

I then pulled the car out and let a few other people dyno their cars while I wrenched on my car in the parking lot.

A couple of hours later I was back in to do three more runs. The verdict: 32 WHP more with the new intercoolers.

I am running REVO stage 3 software, on RS4 K04s, with greentops and a custom 88mm MAF. The car is running a little lean on the top end, likely due to the stock fuel pump I am still running.

The first run in the morning, I put down 307WHP on the dyno dynamics chassis dynamometer. On the second run, I lost 9WHP to heat soak. On the third run, the WHP had dropped more than 20WHP. Intake air temperatures reached 230F after the third run.

With the new intercoolers installed, the first run yielded 339WHP, with subsequent runs dropping off slightly. Intake air temperatures never went over 165F.

Max torque on the second set of runs was 384ft.lbs, an almost 20 ft.lb gain.

One of the guys there (Thanks Bryan) was nice enough to log some of the runs using ECUx, and used Mark Ps templates to plot the graphs. I am still running very low timing up top, less than 10 degrees, with correction factors of less than 7, so there is room for improvement.

In future builds, the top outlet pipes will be of mandrel bent type, or I may still change the design of the intercooler so that they are a straight run into the Bi-pipe. Depends on what the dyno says about that.

I have uploaded a small video of a few of the runs, which doesn't show much, cause I was too scared to get near the car. The guy "driving" is SCCA rally champion Frank sprongl, of Four Star motorsports, in Georgetown Ontario. They had some scary fast cars there, a few Lancer EVOs (VI and VIIs), and a few STIs. Weird too is that they had probably 5 of 6 shells of what were Audi Coupes of early 80's vintage.

Here are the plots of the pulls:

This first pic is of the comparison between the morning run (SERGIO.003), with the OEM intercoolers in place, and the other plot (SERGIO.023)is of the run with the new intercoolers in place:


This second plot is of the three runs after the intercoolers were installed, compared to the first run with the OEM ones in place.
SERGIO.003: Morning run, OEM intercoolers
SERGIO.023: First run with new intercoolers
SERGIO.024: Second run with new intercoolers
SERGIO.025: Third run with new intercoolers



These are the intercoolers:


Later tonight I'll post pics of the install as well as comparos with the stock intercoolers.

The video:

• S4 on dyno, Right click, save as

[Quattro-X-2]

[Blue2]

[silva]

Email me for info.

[silva]

[jtsai]

[Distinct]

My IATs were peaking to well over 200 and his car's max temps were 160s. I saw the ICs and these things are beautiful. Ambient runs in the dyno room had my car's IATs starting at his peak temperatures. It was hot in there. I had my own cooling issues (see my own post above) but these ICs are just so much better than stock.

Nice work Sergio.

[Mat Indukts Lambos]

Or did you install them & put it right on the dyno? It could be even better, or it could be that it was running a hair lean, while it was adapting to the change in the intake path.

[JBear::FATS]

VAST. Get a cut on the profit, if you can reproduce them at a decent cost, with the RS4 and AWE IC being in the 1k range with hoses etc.

You may need to fabricate some shrouds also.

[Imola Ghost]