custom i/c setup!!!
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'03 E55, Range Rover Sport Supercharged, Ducati 748R
custom i/c setup!!!
here are some quick pics. i won't have any time to get any data logging numbers until after the weekend but i'll share my set-up anyways.
basically a 3 stage system consisting of a new front mount heat exchanger with 72% more capacity than the oem unit, a trunk mounted reservoir to greatly increase capacity and give me the ability to add ice at the track to REALLY help cool the charge air, and what's that hidden behind the rear bumper cover you ask...why that's a second remote mounted heat exchanger with dual 6" fans for good measure. as you can see there is a second johnson cm30 pump mounted at the reservoir with it's twin brother mounted in the stock location. there is PLENTY of flow with just one cm30 on this system but i'm obviously into overkill. after seeing how much water was flowing, i really think the cm90 is too much. and of course, the i/c circuit was separated from the engine cooling circuit.
this is a test system to measure benefits and possibilities so i didn't go all out on hoses or connections. each stage of this system can be duplicated or used separately so the possibility of a "kit" is being tossed around. as i've mentioned, this system may not be the ultimate like vrus' slr system but i'm expecting it to work well.
btw, a very important criteria for me was that the heat exchangers be true bolt-ons with no cutting of bumpers or brackets so the car can EASILY be returned to stock. the only permanent mods are the holes for cooling lines to the reservoir which can be plugged if removal is necessary.
basically a 3 stage system consisting of a new front mount heat exchanger with 72% more capacity than the oem unit, a trunk mounted reservoir to greatly increase capacity and give me the ability to add ice at the track to REALLY help cool the charge air, and what's that hidden behind the rear bumper cover you ask...why that's a second remote mounted heat exchanger with dual 6" fans for good measure. as you can see there is a second johnson cm30 pump mounted at the reservoir with it's twin brother mounted in the stock location. there is PLENTY of flow with just one cm30 on this system but i'm obviously into overkill. after seeing how much water was flowing, i really think the cm90 is too much. and of course, the i/c circuit was separated from the engine cooling circuit.
this is a test system to measure benefits and possibilities so i didn't go all out on hoses or connections. each stage of this system can be duplicated or used separately so the possibility of a "kit" is being tossed around. as i've mentioned, this system may not be the ultimate like vrus' slr system but i'm expecting it to work well.
btw, a very important criteria for me was that the heat exchangers be true bolt-ons with no cutting of bumpers or brackets so the car can EASILY be returned to stock. the only permanent mods are the holes for cooling lines to the reservoir which can be plugged if removal is necessary.
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'03 E55, Range Rover Sport Supercharged, Ducati 748R
thanks for the comments guys!
no but it helps.
the fans are wired into the oem pump circuit so they're controlled to come on anytime the ecu turns on the i/c pump and i have a manual override switch that turns on the pumps and new fans, as well as the rad fan.
most likely it will.........it should last longer!!! in our az summer when temps are over 110, i OFTEN get a little bit of detonation every time i get into more than half throttle because iat's are so damned high. the detonation only lasts for a split second until the ecu can retard timing and dump more fuel but it still happens. this should result in much lower iat's and reduce much of that detonation yielding a safer engine environment as well as giving more power.
most likely it will.........it should last longer!!! in our az summer when temps are over 110, i OFTEN get a little bit of detonation every time i get into more than half throttle because iat's are so damned high. the detonation only lasts for a split second until the ecu can retard timing and dump more fuel but it still happens. this should result in much lower iat's and reduce much of that detonation yielding a safer engine environment as well as giving more power.
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Thread Starter
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'03 E55, Range Rover Sport Supercharged, Ducati 748R
one thing i have noticed is that the i/c pump circuit is on a LOT more than i thought. because of all the talk about having to wire the pump to be on continuously with the evosport upgrade i originally thought that the i/c pump only came on during wot runs or really high iat's. there really was no way to know when the oem pumps were activated since the system was a closed system with no visual or audible cues. now with the fans wired into that sytem and being able to see water moving in the reservoir i've noticed that the oem i/c pump circuit is on almost all the time! granted our temps have been 113 or above lately but i was still surprised. i'll be curious to know how it behaves in the colder months.
anyone know the parameters that control the oem i/c pump circuit?
anyone know the parameters that control the oem i/c pump circuit?
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From: Caribbean/Florida/Colorado
E-ZGO 53hp., 1999 E 430 sport, 2004 E 55, 2008 Tahoe LTZ on 24"s
one thing i have noticed is that the i/c pump circuit is on a LOT more than i thought. because of all the talk about having to wire the pump to be on continuously with the evosport upgrade i originally thought that the i/c pump only came on during wot runs or really high iat's. there really was no way to know when the oem pumps were activated since the system was a closed system with no visual or audible cues. now with the fans wired into that sytem and being able to see water moving in the reservoir i've noticed that the oem i/c pump circuit is on almost all the time! granted our temps have been 113 or above lately but i was still surprised. i'll be curious to know how it behaves in the colder months.
anyone know the parameters that control the oem i/c pump circuit?
anyone know the parameters that control the oem i/c pump circuit?
Great use of the for and aft real-estate, in particular the aft "rear" heat exchanger great idea and nice install, I know you'll be tweaking in the weeks to come. Good job I like it!
Not sure and read it here, 130 IAT and pump on. I could be way wrong,
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'03 E55, Range Rover Sport Supercharged, Ducati 748R
i got out early this morning so i could get some temps near my last data logging session. ambient temp was low-mid 80's and i made 10 runs on a closed course from 30-110mph.
runs 1-2 never got iat's above 120.
runs 3-6 had iat's in the mid-high 120's.
runs 5-8 had iat's in the low to mid 130's
run 9 had iat's in high 130's
run 10 finally peaked at 140.
ZERO detonation! iat's recovered immediately after each run to within 25* of ambient (about 10* cooler than oem and MUCH quicker recovery). i think it's fair to say my i/c system is working now! my last session recorded iat's immediately getting up through the 140's and peaking into the 160's after only 2-3 runs. i'll try some runs with ice in the reservoir next weekend.
runs 1-2 never got iat's above 120.
runs 3-6 had iat's in the mid-high 120's.
runs 5-8 had iat's in the low to mid 130's
run 9 had iat's in high 130's
run 10 finally peaked at 140.
ZERO detonation! iat's recovered immediately after each run to within 25* of ambient (about 10* cooler than oem and MUCH quicker recovery). i think it's fair to say my i/c system is working now! my last session recorded iat's immediately getting up through the 140's and peaking into the 160's after only 2-3 runs. i'll try some runs with ice in the reservoir next weekend.
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From: Toronto , Canada
2018 E63S wagon, 2016 GLE350d, GLE450 on order
nice setup ! I've got a couple of questions,
1) have you had a chance to monitor the flow rate? I am wondering if you are moving the fluid too rapidly for it to be the most effective? just a thought as you are using 2 killer pumps. maybe try slowing down the rate and see if it improves the IAT's ??? what about using a product like water wetter??
2) how long did you wait between runs?
1) have you had a chance to monitor the flow rate? I am wondering if you are moving the fluid too rapidly for it to be the most effective? just a thought as you are using 2 killer pumps. maybe try slowing down the rate and see if it improves the IAT's ??? what about using a product like water wetter??
2) how long did you wait between runs?
Thread Starter
MBWorld Fanatic!
Joined: Jun 2006
Posts: 6,649
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'03 E55, Range Rover Sport Supercharged, Ducati 748R
nice setup ! I've got a couple of questions,
1) have you had a chance to monitor the flow rate? I am wondering if you are moving the fluid too rapidly for it to be the most effective? just a thought as you are using 2 killer pumps. maybe try slowing down the rate and see if it improves the IAT's ??? what about using a product like water wetter??
2) how long did you wait between runs?
1) have you had a chance to monitor the flow rate? I am wondering if you are moving the fluid too rapidly for it to be the most effective? just a thought as you are using 2 killer pumps. maybe try slowing down the rate and see if it improves the IAT's ??? what about using a product like water wetter??
2) how long did you wait between runs?
2. i didn't wait at all between runs...well except for the amount of time it took me to slow down to 30mph each time.
Thread Starter
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'03 E55, Range Rover Sport Supercharged, Ducati 748R
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2005 E55 Wagon
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No longer stock '06 E55, A3 3.2 Quattro, GLE 400d, R107 280SL, Golf Polo
VERY nice setup ... that larger front cooler will do wonders, and basically what I was after getting made up ... I personally would not go to the point of adding rear reservoir and rear rad as I would rather have my "spare". Also I think you reach the point of the I/C being the weak point and no matter how much you cool the fluid it aint going to help much... unless you get some SLR I/Coolers!!!! 
Very sweet front mount design and I love the end tanks - are those plastic - or painted metal?
Yeah this flow thing is interesting I will see how the CM90 performs on my setup which is on back burner at mom as the entire household was wheels up this w/e with flu!
All kit has arrived...just a case of getting under the car to fit it all... could be a 2 hr job or an all day job - we shall see.
Very neatly done ... and the results are there to prove it!
Congrats!
Very sweet front mount design and I love the end tanks - are those plastic - or painted metal?
Yeah this flow thing is interesting I will see how the CM90 performs on my setup which is on back burner at mom as the entire household was wheels up this w/e with flu!
All kit has arrived...just a case of getting under the car to fit it all... could be a 2 hr job or an all day job - we shall see.
Very neatly done ... and the results are there to prove it!
Congrats!
Thread Starter
MBWorld Fanatic!
Joined: Jun 2006
Posts: 6,649
Likes: 207
'03 E55, Range Rover Sport Supercharged, Ducati 748R
VERY nice setup ... that larger front cooler will do wonders, and basically what I was after getting made up ... I personally would not go to the point of adding rear reservoir and rear rad as I would rather have my "spare". Also I think you reach the point of the I/C being the weak point and no matter how much you cool the fluid it aint going to help much... unless you get some SLR I/Coolers!!!!
Very sweet front mount design and I love the end tanks - are those plastic - or painted metal?
Yeah this flow thing is interesting I will see how the CM90 performs on my setup which is on back burner at mom as the entire household was wheels up this w/e with flu!
All kit has arrived...just a case of getting under the car to fit it all... could be a 2 hr job or an all day job - we shall see.
Very neatly done ... and the results are there to prove it!
Congrats!
Very sweet front mount design and I love the end tanks - are those plastic - or painted metal?
Yeah this flow thing is interesting I will see how the CM90 performs on my setup which is on back burner at mom as the entire household was wheels up this w/e with flu!
All kit has arrived...just a case of getting under the car to fit it all... could be a 2 hr job or an all day job - we shall see.
Very neatly done ... and the results are there to prove it!
Congrats!
the custom built end tanks are painted aluminum with the return line coming under the h/e to maintain a true cross flow design instead of the silly u-turn design like the oem unit with inlet and outlet on the same side.
