NX GTi-R The Search For Traction – Part Two

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The next change I made with the NX GTi-R actually had nothing to do with gaining traction. If anything, it might actually result in a reduction. The small front mounted intercooler that I installed on the engine swap was ideal because it fit the limited space available in the nose of the NX1600. It was suitable for low boost but not capable of handling the 12 to 16 lbs of boost that I was now demanding. I called my buddy, Aaron Weir, at Vibrant Performance and we discussed a number of potential intercooler options. All of Vibrant’s intercoolers are made with bar and plate construction. I was looking at some of the Vibrant intercooler assemblies with end tanks, but Aaron quickly pointed out the challenges of fitting that into the car.

My good friend at Vibrant Performance, Aaron Weir, hooked me up with Vibrant's 12833 air to air intercooler core. I showed up at Aaron's house with this wood template – to demonstrate the physical constraints that we were facing.

Aaron built my downpipe a year after I had completed the swap, and I am sure that he recalled bashed knuckles that seem to be a fact of life while working in the cramped engine quarters of the NX with the SR20DET. A custom setup would be the best way to proceed. We settled on the 12833 air to air intercooler core with dimensions of 17.75” x 9.85” x 3.5” and a horsepower rating of approximately 515 HP. That is not something that I will be exceeding or even getting to close to in the immediate future.

I used wood and PVC piping to make the mock ups; Aaron used random pieces of cardboard that were likely in a recycling bin to create templates before cutting into the aluminum. Hopefully the company represented by this cardboard won't mind a bit of advertising.

Aaron also agreed to help me out by building custom end tanks for the NX – there is not much room to spare in this crowded engine bay. The piping is all 2.5” aluminum and both ends are custom designed to fit the NX GTi-R’s engine bay. It was not easy, as the car was up on axle stands and Aaron’s garage was about fifty minutes away. I drew sketches on paper, drafted some on computer, and we talked and discussed how we could make it work. I arrived at the start of the project with a 1”x3” wood frame. Before Aaron could say anything, I described how this was the best way I could think of to physically demonstrate the space limitations that would be limiting factors.

Here's the hot side end tank that has been tacked together. Aaron liked my idea of welding in a couple of diverter plates to direct the air as it's entering the intercooler.

Measure twice and cut once often works, but we found that a tacked together mock-up was best and then allowed for near perfection in the crowded quarters of my engine bay. The end pipes needed to just clear the radiator by 1/2″. The 1.5″ shown in the insert on the top left would have caused a few other clearance issues.