Just sharing some progress
Thread Starter
MBWorld Fanatic!
Joined: Jul 2014
Posts: 3,331
Likes: 586
2005 e55 AMG
Just sharing some progress
Thought I would share some inter cooler work that I completed. All the information I have researched and received from this forum has been fantastic so before I start I just wanted to say thanks. So this is what I did.
Bought a universal inter cooler off Ebay and made it a two pass setup.Put it in the stock location. Took another inter cooler, a mini cooper aluminum radiator and mounted it on the drivers side behind the fog light. Of course had to remove the fog lights and put new mesh in its place.
I have two CM30 pumps, one pushes through the system and one pushes out so to speak.
Took the supercharger off and cut open the lower inter cooler removing the two side tanks. Cut the tanks off and made it into a two pass, dual feed , dual outlet/return setup.Never new it was a single feed three pass set up. Now I have cool water passing through front and rear. Also got a little crazy and stripped down the blower ,greased her up and welded close the two silencer holes and ported the inlet for a 82mm throttle body. This sucker SCREAMS under boost!! I love it.
So total end results..... Completely stock looking set up... unless you own one of these cars you could not tell anything different.
Temperatures cruising are at the same temperature as it is outside,highway only. When supercharger is engaged on temps are 5-10 degrees above ambient and an all out red line pull through 3-4 gear temps never go over 105 degrees on a 80* day. Works perfect. On a 70* day we had, temps stay around 95-100* on very hard pulls .So all an all.... $150.00 for the two coolers off Ebay and a lot of labor/love/welding and its a total win!! Unfortunately my camera card has disappeared so no pictures. I'm searching!! So thanks to all on this forum,.....
Bought a universal inter cooler off Ebay and made it a two pass setup.Put it in the stock location. Took another inter cooler, a mini cooper aluminum radiator and mounted it on the drivers side behind the fog light. Of course had to remove the fog lights and put new mesh in its place.
I have two CM30 pumps, one pushes through the system and one pushes out so to speak.
Took the supercharger off and cut open the lower inter cooler removing the two side tanks. Cut the tanks off and made it into a two pass, dual feed , dual outlet/return setup.Never new it was a single feed three pass set up. Now I have cool water passing through front and rear. Also got a little crazy and stripped down the blower ,greased her up and welded close the two silencer holes and ported the inlet for a 82mm throttle body. This sucker SCREAMS under boost!! I love it.
So total end results..... Completely stock looking set up... unless you own one of these cars you could not tell anything different.
Temperatures cruising are at the same temperature as it is outside,highway only. When supercharger is engaged on temps are 5-10 degrees above ambient and an all out red line pull through 3-4 gear temps never go over 105 degrees on a 80* day. Works perfect. On a 70* day we had, temps stay around 95-100* on very hard pulls .So all an all.... $150.00 for the two coolers off Ebay and a lot of labor/love/welding and its a total win!! Unfortunately my camera card has disappeared so no pictures. I'm searching!! So thanks to all on this forum,.....
Last edited by SICAMG; Sep 21, 2016 at 08:54 PM.
Junior Member
Joined: Jun 2016
Posts: 34
Likes: 5
From: SoCal
2004 E55
Thought I would share some inter cooler work that I completed. All the information I have researched and received from this forum has been fantastic so before I start I just wanted to say thanks. So this is what I did.
Bought a universal inter cooler off Ebay and made it a two pass setup.Put it in the stock location. Took another inter cooler, a mini cooper aluminum radiator and mounted it on the drivers side behind the fog light. Of course had to remove the fog lights and put new mesh in its place.
I have two CM30 pumps, one pushes through the system and one pushes out so to speak.
Took the supercharger off and cut open the lower inter cooler removing the two side tanks. Cut the tanks off and made it into a two pass, dual feed , dual outlet/return setup.Never new it was a single feed three pass set up. Now I have cool water passing through front and rear. Also got a little crazy and stripped down the blower ,greased her up and welded close the two silencer holes and ported the inlet for a 82mm throttle body. This sucker SCREAMS under boost!! I love it.
So total end results..... Completely stock looking set up... unless you own one of these cars you could not tell anything different.
Temperatures cruising are at the same temperature as it is outside,highway only. When supercharger is engaged on temps are 5-10 degrees above ambient and an all out red line pull through 3-4 gear temps never go over 105 degrees on a 80* day. Works perfect. On a 70* day we had, temps stay around 95-100* on very hard pulls .So all an all.... $150.00 for the two coolers off Ebay and a lot of labor/love/welding and its a total win!! Unfortunately my camera card has disappeared so no pictures. I'm searching!! So thanks to all on this forum,.....
Bought a universal inter cooler off Ebay and made it a two pass setup.Put it in the stock location. Took another inter cooler, a mini cooper aluminum radiator and mounted it on the drivers side behind the fog light. Of course had to remove the fog lights and put new mesh in its place.
I have two CM30 pumps, one pushes through the system and one pushes out so to speak.
Took the supercharger off and cut open the lower inter cooler removing the two side tanks. Cut the tanks off and made it into a two pass, dual feed , dual outlet/return setup.Never new it was a single feed three pass set up. Now I have cool water passing through front and rear. Also got a little crazy and stripped down the blower ,greased her up and welded close the two silencer holes and ported the inlet for a 82mm throttle body. This sucker SCREAMS under boost!! I love it.
So total end results..... Completely stock looking set up... unless you own one of these cars you could not tell anything different.
Temperatures cruising are at the same temperature as it is outside,highway only. When supercharger is engaged on temps are 5-10 degrees above ambient and an all out red line pull through 3-4 gear temps never go over 105 degrees on a 80* day. Works perfect. On a 70* day we had, temps stay around 95-100* on very hard pulls .So all an all.... $150.00 for the two coolers off Ebay and a lot of labor/love/welding and its a total win!! Unfortunately my camera card has disappeared so no pictures. I'm searching!! So thanks to all on this forum,.....
Super Member
Joined: Jul 2006
Posts: 789
Likes: 36
2006 E55
I will let others ( The guys who are extremely well respected that know their crap inside and out ) comment. However, if you did what you claim you did to me this sounds epic.
I also have to ask "what are your credentials"? Are you an engineer by trade some type of hotshot mechanic?
pictures please.
tk
I also have to ask "what are your credentials"? Are you an engineer by trade some type of hotshot mechanic?
pictures please.
tk
MBWorld Fanatic!
Joined: Aug 2012
Posts: 1,790
Likes: 109
From: DownEast Maine
CLS 55 AMG E500 ML320
I like what you did with the intercooler. If you ran cold in on opposite sides, both banks should get about the same temperature air. I don't understand welding up two silencer holes. On my S/C, the silencer is one whole corner of the outlet blocked off with a cut down the middle. I almost cut it all out, but didn't want to listen to part throttle S/C whine all the time.
Thread Starter
MBWorld Fanatic!
Joined: Jul 2014
Posts: 3,331
Likes: 586
2005 e55 AMG
StarvingArtist the supercharger idea came from you in one of your post's a while back. Someone asked what the slots where and you said it was for sound so i researched from there.Also I know someone that cut everything out and lost boost so I did not want to do that!
MBWorld Fanatic!
Joined: Nov 2007
Posts: 3,681
Likes: 39
From: San Diego
E55
Wow, those temps sound amazing! You do not even get hot enough for the ecu to start pulling timing. Your full advance all the way through a hard redline pull. That's great! 
Pics would be nice, Congrats!
Pics would be nice, Congrats!
Super Member
Joined: Oct 2012
Posts: 637
Likes: 40
From: Keller
clk63, cls55, ml63, (w210) E55
First off, I apologize...up front...on my questioning of this set-up!
Second off, awesome job thinking outside the box!
That defies physics on heat transfer? The water will be above ambient by default. How would heated water cool the intercooler core that is being heated by hot air and heat soak (heated metal to metal contact) to ambient temps?
*Other than having factory boost with ported heads and long tube headers with your intercooler set up.....this defies our factory blower efficiency.
Let me explain why I'm asking....
I have a 4 gallon intercooler system with 3 heat exchangers/ 3 factory sized intercoolers/ 3 CM30 pumps. With......
Ported heads (reduces boost)
Long tube headers w/o cats (reduces boost)
Intake that doesn't suck in engine heat
Single pass factory intercooler
3/4 intercooler piping
17-18 psi of boost
Results with 96 degree ambient temps...
-10 degrees above ambient at highway speeds with supercharger never engaged
-18-22 degrees above ambient at highway speeds (70mph) with heat soaked engine (takes @3-5 minutes to bring temps down to this level)
-0-140 mph WOT yields anywhere from 8-16 degree increase from starting IAT's (meth/water keeps me at to below starting IAT's)
As stated before, heat exchangers do little on helping IAT's under boost. It's the intercooler surface area. Again, please take no offense!
*if so, please disregard my above post. lol
Second off, awesome job thinking outside the box!
*Other than having factory boost with ported heads and long tube headers with your intercooler set up.....this defies our factory blower efficiency.
Let me explain why I'm asking....
I have a 4 gallon intercooler system with 3 heat exchangers/ 3 factory sized intercoolers/ 3 CM30 pumps. With......
Ported heads (reduces boost)
Long tube headers w/o cats (reduces boost)
Intake that doesn't suck in engine heat
Single pass factory intercooler
3/4 intercooler piping
17-18 psi of boost
Results with 96 degree ambient temps...
-10 degrees above ambient at highway speeds with supercharger never engaged
-18-22 degrees above ambient at highway speeds (70mph) with heat soaked engine (takes @3-5 minutes to bring temps down to this level)
-0-140 mph WOT yields anywhere from 8-16 degree increase from starting IAT's (meth/water keeps me at to below starting IAT's)
As stated before, heat exchangers do little on helping IAT's under boost. It's the intercooler surface area. Again, please take no offense!
*if so, please disregard my above post. lol
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Thread Starter
MBWorld Fanatic!
Joined: Jul 2014
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2005 e55 AMG
Well I new this was coming so I will give it a shot than delete the post, not that it will help, so I do not stir anything up anymore LOL
"Temperatures cruising are the same as outside temperatures, highway only"
Why not? The supercharger is not spinning, just floating along with no engagement, no heat being produced and pumps running. The only heat being combated is whatever the outside temp is and whatever heat is soaking in the intake valley. It dose not have to defy physics because NO heat is being produced. The temperature will be the same. No? I may be way off with this theory LOL.
Next. "When supercharger is engaged temps are 5-10 above ambient"
Yes. All that is going on now is the blower is just puttin' along with really no load or compression of air because the engine is still in a vacuum state, no load very,very little heat being produced and just cruising down the highway with supercharger engaged. I always will say highway because that's where the most air is being pushed through the coolers. City driving..... totally different with little air flow and much higher temperatures all around.
If I am wrong than I clearly have posted a huge blunder and apologize. But my temperature gauge tells me I have gone in the right direction as compared to before this project.No worry's and thanks for the input Erebus!
"Temperatures cruising are the same as outside temperatures, highway only"
Why not? The supercharger is not spinning, just floating along with no engagement, no heat being produced and pumps running. The only heat being combated is whatever the outside temp is and whatever heat is soaking in the intake valley. It dose not have to defy physics because NO heat is being produced. The temperature will be the same. No? I may be way off with this theory LOL.
Next. "When supercharger is engaged temps are 5-10 above ambient"
Yes. All that is going on now is the blower is just puttin' along with really no load or compression of air because the engine is still in a vacuum state, no load very,very little heat being produced and just cruising down the highway with supercharger engaged. I always will say highway because that's where the most air is being pushed through the coolers. City driving..... totally different with little air flow and much higher temperatures all around.
If I am wrong than I clearly have posted a huge blunder and apologize. But my temperature gauge tells me I have gone in the right direction as compared to before this project.No worry's and thanks for the input Erebus!
Last edited by SICAMG; Sep 21, 2016 at 09:59 PM.
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MBWorld Fanatic!
Joined: Aug 2012
Posts: 1,790
Likes: 109
From: DownEast Maine
CLS 55 AMG E500 ML320
Still don't understand what you welded??? If no pics, how about a sketch.
Super Member
Joined: Oct 2012
Posts: 637
Likes: 40
From: Keller
clk63, cls55, ml63, (w210) E55
*Side note?
That shading on the outlet of the supercharger posted above was removed during some work on the blower. Finney played with this area years ago and I followed suit. Gains? .5-.75 psi gain across the board. You can't help to feel the increase of boost with the damn noise the blower makes. Placebo effect? Yes. No improvement in lowered IAT's, though.
*sorry for the hijack.
Super Member
Joined: Oct 2012
Posts: 637
Likes: 40
From: Keller
clk63, cls55, ml63, (w210) E55
Holster your weapon, soldier. We are petrol burning gearheads, here. Information is KEY for our survival in a transforming world of hybrids and pedal powered transportation.
"Temperatures cruising are the same as outside temperatures, highway only"
Why not? Physics. Your engine is nothing more than a container designed to manage thousands of heat generating explosions per minute. Heat, of course, is the by-product that transfers to ALL components by either radiant or physical contact. The supercharger is not spinning, just floating along with no engagement, no heat being produced and pumps running. The only heat being combated is whatever the outside temp is and whatever heat is soaking in the intake valley. It dose not have to defy physics because NO heat is being produced. Incorrect. I tested my ML63 and CLK63 with my TORQUE app and have found I have IAT's 30-40 degrees above ambient a moderate speeds. 10-20 degrees above ambient at highway speeds. N/A engines, mind you. The temperature will be the same. No? No. I may be way off with this theory LOL. Kinda. lol
Next. "When supercharger is engaged temps are 5-10 above ambient"
Yes. No. All that is going on now is the blower Please is just puttin' along with really read no load or compression my of air because the engine above is still in a vacuum state, post no load very,very little heat for being produced and just cruising down the highway with supercharger engaged. I always the will say highway because explanation. that's where the most air is being pushed through the coolers. City driving..... totally different with little air flow and much higher temperatures all around. Correct. It is different. Long term city driving will HEAT SOAK your engine/blower to temps that will take a while to bring back down.
If I am wrong than I clearly have posted a huge blunder and apologize. No apology needed. Please send donations to www.midgetpornstarsneedlovetoo.com But my temperature gauge tells me I have gone in the right direction as compared to before this project. No worry's and thanks for the input Erebus! Brah, I won't quit you. Oh wait, what?
Why not? Physics. Your engine is nothing more than a container designed to manage thousands of heat generating explosions per minute. Heat, of course, is the by-product that transfers to ALL components by either radiant or physical contact. The supercharger is not spinning, just floating along with no engagement, no heat being produced and pumps running. The only heat being combated is whatever the outside temp is and whatever heat is soaking in the intake valley. It dose not have to defy physics because NO heat is being produced. Incorrect. I tested my ML63 and CLK63 with my TORQUE app and have found I have IAT's 30-40 degrees above ambient a moderate speeds. 10-20 degrees above ambient at highway speeds. N/A engines, mind you. The temperature will be the same. No? No. I may be way off with this theory LOL. Kinda. lol
Next. "When supercharger is engaged temps are 5-10 above ambient"
Yes. No. All that is going on now is the blower Please is just puttin' along with really read no load or compression my of air because the engine above is still in a vacuum state, post no load very,very little heat for being produced and just cruising down the highway with supercharger engaged. I always the will say highway because explanation. that's where the most air is being pushed through the coolers. City driving..... totally different with little air flow and much higher temperatures all around. Correct. It is different. Long term city driving will HEAT SOAK your engine/blower to temps that will take a while to bring back down.
If I am wrong than I clearly have posted a huge blunder and apologize. No apology needed. Please send donations to www.midgetpornstarsneedlovetoo.com But my temperature gauge tells me I have gone in the right direction as compared to before this project. No worry's and thanks for the input Erebus! Brah, I won't quit you. Oh wait, what?
