So can you tell me what the full size and mini intercooler weigh? And with the drop in charge temps , what can we get in horsepower ? Will a full size intercooler get me 2 hp ? 3hp? 5hp ? 20 hp?
I am just focused on HP per LB ratio's on the sleds . If you add weight you had better come up with alot of HP to pay for that weight . I would love to hear from a BD employee , why the intercooler is worth the weight.
Here it goes; as an example we’ll use an 800cc engine, running 8200 RPM, at 8000 ft elevation, and 32° ambient air temp
If we take our test subject and boost it 8 psi, with a reasonable turbo compressor efficiency of 72%, our compressor temp rise would be 116 ° added that to our ambient air temp of 32°, we would have a charge air temp of 148° and make approximately 194.7 HP.
Now if we were to add an intercooler that is 60% effective, our charge air temp would drop 70° leaving us with a charge air temp of 78° and make approximately 220.1 HP, a 13% HP gain.
Let’s take our test sled and bump it up to 15 psi. If we use the same compressor efficiency of 72% our compressor temp rise would be 185° added to our ambient air temp of 32°, we would have a charge air temp of 217° and make approximately 239.6 HP.
Note; at this kind of charge air temp you would most like experience detonation, which could possibly be suppressed by adding extra fuel, but would also result in a loss of HP and fuel economy.
Now if we were to add an intercooler that is 60% effective, our charge air temps would drop 111° leaving us with a charge air temp of 106° and make approximately 286.6 HP, a 20% HP gain, and no detonation.
The mini intercooler for the BD pump gas turbos weighs about 4.5 lb. and the larger race gas intercooler weighs about 9 lb. The way I see it if you building charge air temps in the 200 plus range the weight of the extra fuel you’ll carry so you can wash down detonation, will alone justify the weight of an intercooler. Not to mention the added HP and dependability, pistons ain’t cheep these days.
Junior