New (SMART) Intercooler for me - well reccomended!
Turbo Mini Forums

Awight guys, after picking up a diesel sierra diff from a breakers in bolton on friday (bought for 20 quid, sold yesterday for 80!!!!) i saw an intercooler i believe to be off a Smart sat in the corner. I immediately saw it's potential - even more so when the word "fiver" was heard after the price was enquired!

So, why do i like this intercooler?
Ok - in standard form, it's pretty pants! 35mm(ish) inlet and outlet pipes, but use the core only, and make two new end caps, and it's a champion little thing!

Here is a pic of it as standard


And here is a pic of the core close-up


As you can see, we have lots of 'fins' per square inch. We also have potential for a very large 'internal area' (the area the charge air passes through). I say 'potential' because in it's current form, the air goes through only half the intercooler, then into the left-hand cap, and out again - so internal area is only half it's potential in the picture shown - ideal for a 600cc engine in a Smart however!!!!

Internally, there are also lots of 'turbulators' (fins) to maximinse the internal area. Obviously, the more internal area, the greater the chance the air will want to 'give up' its heat. You need to draw the balance of turbulators vs restriction however!!!

In this picture, you can see it compared to my current RST (Series 2) intercooler.

Perspective is playing a little trick though, as the core is only 10mm longer in reality! Note how the internal area is greater however - by 40% by my estimation.

Here is a close-up of the Escort unit, showing why i chose it

A nice, compact fin design, large internal area (unlike the series 1 RST unit, and LandRover 2/300TDi to name two examples).

Hopefully, i'll have the endcaps off tonight, and start knocking up some new ones.

Edited by turbodave16v on 7th Jun, 2004.

i think somebody on here has bought one of them recently off ebay and theres had a fan on it too

no longer a series, but still 1.3 turbo.

i bought one in january but havent fitted it yet,looks different to mine though.... http://cgi.ebay.co.uk/ws/eBayISAPI.dll?Vie...item=7900884702

i bought a fiat uno intercooler for ?5.99, how does that sound??

it may b small but it purfectly formed
http://photobucket.com/albums/v340/1976_mi...roject%20turbo/

So how do you plan to change the end caps + pipes? Please keep my updated as this is very interesting....

if in right the end caps are only held on by floded over alloy which is easily bent back over to remove the caps, but i wouldnt no how you would go about making new caps!
hope that helps, si

it may b small but it purfectly formed
http://photobucket.com/albums/v340/1976_mi...roject%20turbo/

If you have a go at changing the end cap you'll need to get it pressure tested

Edited by Soton1310Turbo on 8th Jun, 2004.

As you can see Dave's new intercooler has plastic end caps and an alloy core... all you do is unclip the plastic ends and weld on some new (but very carefully designed) new end caps!

Alex

AlexF

I won't be pressure testing it. Do it properly and this is not needed!
Will be using 2mm rolled Ally sheet for the endcaps.

WHy test it...

You can test if its leaking by looking at it and listening!

alex

AlexF

Alex, please explain in more detail your "looking and listening" method?

Edited by giallofly on 8th Jun, 2004.

maybe you piss on it with the engine running, and look and listen for the bubles?

Team Racing

id use leak check spray jim, we've found at work it gives more consitant bubbles than piss!

any of the day id block up both ends, apply a low pressure, say 10/20psi and then just use leak check spray. Either that or immerse each end in water, sure that would do the trick!

Thats the one...

leak check spray.. if your running on the engine to check it...

I'd personally put it in the bath and pressurise it to a few psi... leaks of consequence will sonn be apperent!


:p

alex

AlexF

i won`t try the bath method but i can`t get the car in the front door never mind up he stairs to the bath

Everyone knows that instructions only have to be read if the thing doesn't work....

what about another bath in the gagrage mark?

I got a spare here if you wanna try it

LOL

alex

AlexF

4 mini`s , 2 astra`s ( don`t ask) 2 car trailers , 30+ wheels/tyres , shit loads of spares .... no room for a bath

Everyone knows that instructions only have to be read if the thing doesn't work....

2 trailers... lucky git

I only have 2 minis, 1 rs, 2 firenzas. 1 camper van, one mini sized trailer and about the same numebr of wheels!!

Alex

AlexF

i have 1 mini about 5 wheels and 4 push bikes so you both beat me

9 mini`s all told other in lockups elsewhere

Everyone knows that instructions only have to be read if the thing doesn't work....

9?!

What have you got?

I got the turbo thing and a rusty clubby I don't know what to do with!!

Alex

AlexF

Mark is a hoarder. Never gets rid of anything mini related. One of those people who will, at the age of 75, still have 9+ minis in various lockups with the intention of 'doing something with them one day'...

Jon F's the same, but he only collects used knickers!

Team Racing

to get things done by the time i`m 75 , if i live that long, i`ll better go a move on. not long till i`m 75.might have won a trophy a avon by then.lol.

stock list :-
2 turbo`s
2 vans
2 saloon`s
1 scamp thing
1 marcos
1 spare shell
think thats all ?

Everyone knows that instructions only have to be read if the thing doesn't work....

no one has brought your old turbo????


Alex

AlexF