Are there any gains to be had just by changing the intercooler (say to a Herrod one)?

Edit: Sorry for the typo in the heading, my fingers are faster than my brain!

Edited 17/02/03 08:56 PM17/02/03 08:56 PM by Falchoon

I believe Rob Herrod has the intercooler made up. So its obvious that gains will be made.

Theoretically you'll have the ability to cool the air better so on warmer days, definitely. On cooler days, it probably won't make a difference. Just watch your torque levels at lower RPMs as a bigger intercooler often comes with more top end power with some losses at lower RPM, particularly if the boost isn't turned up to compensate, I think

A larger intercooler will have a larger pressure drop then a smaller one.

A larger intercooler will result in cooler air intake during extended boost operation.

By it self a larger intercooler would at best result in poorer low down performance but better power during extended boost operaqtion.

In normal road driving boost is normally only used for short lengths of time - 15seconds gets you from 0 -160km/hr so you wouldnt be boosting for longer then that normally (unless going up ranges, or towing....)

A larger intercooler would become important if other mods were being done at the same time. So I suspect that Herrods would be changing the intercooler at the same time as other things (new exhaust, changes in the ECU, more boost....)

Back to the drawing board then, don't want to loose any low end power, if anything want more!

The rule of thumb for Turbo charged cars is that the first step is to upgrade the exhaust (unless the manufacturer has alreeady been there looking for power - in this case Ford hasnt)

I belive CJF077 has already done this - no posted power improvment yet (I dont think).

You wont necessarily loose bottom end power.

It seems in Ford circles no one has any hard information.

Mass produced intercoolers are most often cheap and not optimised for efficiency.

You would need to measure the inlet and outlet temperatures, as well as the pressure drop through the standard intercooler. You would then conduct a range of thermodyanic caculations to figure efficiencies.

If you designed the heat exchanger for best performance and not cost and quickness to fit, its highly likely you will end up with less pressure loss and more scrubbing of heat than the factory.

However, a badly done intercooler can definately be worse than having none!

This is why the ability to weld is nothing in comparison to the ability to design one properly and is why a real intercooler is going to be over $AUS2000.

This is all academic anyway as arent we still waiting for the ECU to be cracked?

Yes, a aftermarket intercooler will surely do some good for the XR6T...the standard intercooler is really small. I thought the one on mine was small till I saw the BA XR6T ones up close and personal. However, I'm not so sure if there's any space allowance behind the bumper bar for a larger intercooler...you'll also have to think about your radiator, don't want the huge-ass big mama intercooler to block too much of it too. Which is also why mine was custom made with a slant top :D

This is all academic anyway as arent we still waiting for the ECU to be cracked?

Some of the guys have experience some performance degradation on hot days which is why I think they are interested in the larger intercooler.

Jesmal im wondering where you got your intercooler from??? Is it the TSA style cooler they use it the stage 2 kit???