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Well I've been looking for upgrades available in the aftermarket for my CL65, and honestly the price to performance of the majority of "bolt on" products available have me looking at making my own parts to install. Here is a little project I've been working on. Designed a quad inter cooler system in solid works that fits underneath the stock engine covers of the M275 amg! I took the measurements on my car, so non AMG dimensions may not be compatible. The second inter-cooler core takes the place of the stock air-box, so a custom cold air intake solution must be used. I'm working on a design in solid works for that as well. I am going to contact bell inter-coolers to get a price estimate on how much they would cost for them to fabricate once I finish the design. Still need to add in the mount points for the engine and the engine covers. Really want to make this as "plug and play" as possible. It uses one of their off the shelf W2A inter cooler cores. Product code: AW600037060 (6" x 6"x 3.7" dimensions). Since you need 4 of them it's about 800 total not including fabrication. I'd guesstimate price of around $1.1-1.3k per assembly, about $2.5k total. 1/4" npt threads for water lines so hardware can easily be sourced. 2" air inlets/outlets. Waterlines would be adapted to the stock feed and return line on the engine. You could have one cooler feed the second, or T of the two feed lines so each core gets fresh water(this may be a tight fit under the engine, however.) Charge pipes and merger pipe I personally think would be easier for the installer to fabricate for their specific application, thus not included in the design. Let me know what you guys think. I also could easily modify the design to have 4-5 inch tall inter-cooler cores, giving you better cooling performance, but It was my goal to maintain a stock appearance under the hood. I may be bias, but I think the M275 engine is ugly without them
Let me know what you guys think, and if any changes should be taken into consideration!
Very interesting, but I wouldn't get too ambitious until you trial fit some mock-ups. It's a tight space in there.
The turbo outlets bend backwards and will make the charge air pipe difficult to design.
Here's a valuable tip for free, this is what MB did, and few people realise what good design it was. Plumb the water in series, not parallel, but be sure to run the cold water inlet into the downstream cooler first. That way you get a counter-flow heat exchanger, which is always the most efficient configuration. It's the only way to get the outlet air cooler than the outlet water. I can explain more if needed.
Very interesting, but I wouldn't get too ambitious until you trial fit some mock-ups. It's a tight space in there.
The turbo outlets bend backwards and will make the charge air pipe difficult to design.
Here's a valuable tip for free, this is what MB did, and few people realise what good design it was. Plumb the water in series, not parallel, but be sure to run the cold water inlet into the downstream cooler first. That way you get a counter-flow heat exchanger, which is always the most efficient configuration. It's the only way to get the outlet air cooler than the outlet water. I can explain more if needed.
Nick
Thanks for the advice. And yes if you could PM me more of an explanation about the water being in series and why is more efficient, that would be helpful. I'll see if I can get some 3d printed prototypes created first. Last thing I want to do I drop money on a custom intercooler that doesn't even fit.
In my opinion, there are 2 critical things to think about with larger intercoolers:
1.The additional surface area for heat transfer acts like an obstruction to airflow. Stock turbos cannot maintain boost in the higher RPMs, so the larger intercoolers will only make this worse.
2. Obviously bigger intercoolers are used to absorb more heat. The problem becomes quicker heat soak if additional heat exchanges or a killer chiller isn't used to help lower the fluid temperature.
If you plan on going with larger intercoolers, plan on other supporting mods to battle the heat they absorb. You'll find there are more costs involved in making them function effectively.
In my opinion, there are 2 critical things to think about with larger intercoolers:
1.The additional surface area for heat transfer acts like an obstruction to airflow. Stock turbos cannot maintain boost in the higher RPMs, so the larger intercoolers will only make this worse.
2. Obviously bigger intercoolers are used to absorb more heat. The problem becomes quicker heat soak if additional heat exchanges or a killer chiller isn't used to help lower the fluid temperature.
If you plan on going with larger intercoolers, plan on other supporting mods to battle the heat they absorb. You'll find there are more costs involved in making them function effectively.
