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Project S2000: Part 26 – Air to Water Intercooler Setup

  • Khiem Dinh

About two weeks after my initial sketch, I had the final product from Bell Intercoolers in my hands. It was fabricated in San Antonio, Texas, so being made in the USA cut down on shipping. I could have had it even faster if I paid for quicker shipping, but there is no rush and I need to save money where I can. The intercooler came very securely packed to prevent shipping damage. The intercooler was sealed in a bag and all the hose connections had red caps to prevent anything from getting into the intercooler. Notice the water end tanks have a depth of 1.5” to allow for good water distribution across the core.

Looking inside the air inlet side of the intercooler, you can see the air guide to help get more equal flow distribution across the core for better effectiveness. This side has the 2” inlet, so the end-tank has a slight taper. You can see how the air will have expand just a little bit going into the end tank.

On the outlet side with the 2.5” hose connection, the airflow has to make a minimal step. An important characteristic of the air-to-water core is the difference in flow path heights for the water flow and the air flow. We couldn’t get a good picture through the small ¾” hose barb for the coolant, but if you look inside, can you see the coolant flow paths through the core are smaller. Coolant having much higher heat capacity than air requires much lower flowrate. So, in an air-to-water core, the flow path width is biased to be greater for the airflow which also reduces the airflow pressure drop. We definitely like minimal airflow pressure drop.

I measured the front bumper opening at roughly 27” wide and 6” tall. In the middle is the receiver/dryer for the air conditioning system.

The distance from the receiver/dryer to the back of the black plastic grill is about 2”.

Previous page 1 2 3Next page
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  • Intercooler
  • Honda S2000
  • Bell Intercoolers
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These Old Photos, NHRA Xplod Series Final October 22, 2006

  • Mike Kojima
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SlipAngle Podcast /// Chop Top Challenge and Race Prep for Mid-Ohio

  • Abrin Schmucker
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24 comments
  1. Kevski-Style says:
    March 25, 2019 at 5:15 pm

    Looks like Garrett just released an updated video and they have something now called DualBoost Twin-Flow.
    https://www.garrettmotion.com/news/video-center/video/dualboost-twin-flow/

    No clue on the turbo making it to production, but you can bug Mike Stoller about it. He posted his email in the comments section of my article on the DB:
    https://motoiq.com/the-secret-turbo-in-the-ring-slaying-porsche-919-evo-honeywell-garrett-dualboost-for-gasoline-turbocharger/

    With gas turbo engines, at WOT, the wastegate flow is typically like 30%-40% of total flow. On the 919, all that wastegate flow goes through a turbine which spins an electric generator, so basically waste heat recovery. With a track like Le Mans where the car is at WOT for long stretches, it generates a lot of energy!

    Reply
    1. Khiem Dinh says:
      March 25, 2019 at 6:13 pm

      Looks like Garrett just released an updated video and they have something now called DualBoost Twin-Flow.
      https://www.garrettmotion.com/news/video-center/video/dualboost-twin-flow/

      No clue on the turbo making it to production, but you can bug Mike Stoller about it. He posted his email in the comments section of my article on the DB:
      https://motoiq.com/the-secret-turbo-in-the-ring-slaying-porsche-919-evo-honeywell-garrett-dualboost-for-gasoline-turbocharger/

      With gas turbo engines, at WOT, the wastegate flow is typically like 30%-40% of total flow. On the 919, all that wastegate flow goes through a turbine which spins an electric generator, so basically waste heat recovery. With a track like Le Mans where the car is at WOT for long stretches, it generates a lot of energy!

      Reply
  2. Kevski-Style says:
    March 26, 2019 at 3:46 am

    Looks like Garrett just released an updated video and they have something now called DualBoost Twin-Flow.
    https://www.garrettmotion.com/news/video-center/video/dualboost-twin-flow/

    No clue on the turbo making it to production, but you can bug Mike Stoller about it. He posted his email in the comments section of my article on the DB:
    https://motoiq.com/the-secret-turbo-in-the-ring-slaying-porsche-919-evo-honeywell-garrett-dualboost-for-gasoline-turbocharger/

    With gas turbo engines, at WOT, the wastegate flow is typically like 30%-40% of total flow. On the 919, all that wastegate flow goes through a turbine which spins an electric generator, so basically waste heat recovery. With a track like Le Mans where the car is at WOT for long stretches, it generates a lot of energy!

    Reply
    1. Khiem Dinh says:
      March 26, 2019 at 7:51 am

      Looks like Garrett just released an updated video and they have something now called DualBoost Twin-Flow.
      https://www.garrettmotion.com/news/video-center/video/dualboost-twin-flow/

      No clue on the turbo making it to production, but you can bug Mike Stoller about it. He posted his email in the comments section of my article on the DB:
      https://motoiq.com/the-secret-turbo-in-the-ring-slaying-porsche-919-evo-honeywell-garrett-dualboost-for-gasoline-turbocharger/

      With gas turbo engines, at WOT, the wastegate flow is typically like 30%-40% of total flow. On the 919, all that wastegate flow goes through a turbine which spins an electric generator, so basically waste heat recovery. With a track like Le Mans where the car is at WOT for long stretches, it generates a lot of energy!

      Reply
      1. Kevski-Style says:
        March 26, 2019 at 8:01 am

        Looks like Garrett just released an updated video and they have something now called DualBoost Twin-Flow.
        https://www.garrettmotion.com/news/video-center/video/dualboost-twin-flow/

        No clue on the turbo making it to production, but you can bug Mike Stoller about it. He posted his email in the comments section of my article on the DB:
        https://motoiq.com/the-secret-turbo-in-the-ring-slaying-porsche-919-evo-honeywell-garrett-dualboost-for-gasoline-turbocharger/

        With gas turbo engines, at WOT, the wastegate flow is typically like 30%-40% of total flow. On the 919, all that wastegate flow goes through a turbine which spins an electric generator, so basically waste heat recovery. With a track like Le Mans where the car is at WOT for long stretches, it generates a lot of energy!

        Reply
  3. Avatar photo Mike Kojima says:
    March 26, 2019 at 12:46 pm

    Looks like Garrett just released an updated video and they have something now called DualBoost Twin-Flow.
    https://www.garrettmotion.com/news/video-center/video/dualboost-twin-flow/

    No clue on the turbo making it to production, but you can bug Mike Stoller about it. He posted his email in the comments section of my article on the DB:
    https://motoiq.com/the-secret-turbo-in-the-ring-slaying-porsche-919-evo-honeywell-garrett-dualboost-for-gasoline-turbocharger/

    With gas turbo engines, at WOT, the wastegate flow is typically like 30%-40% of total flow. On the 919, all that wastegate flow goes through a turbine which spins an electric generator, so basically waste heat recovery. With a track like Le Mans where the car is at WOT for long stretches, it generates a lot of energy!

    Reply
  4. stylngle2003 says:
    March 27, 2019 at 4:27 am

    Looks like Garrett just released an updated video and they have something now called DualBoost Twin-Flow.
    https://www.garrettmotion.com/news/video-center/video/dualboost-twin-flow/

    No clue on the turbo making it to production, but you can bug Mike Stoller about it. He posted his email in the comments section of my article on the DB:
    https://motoiq.com/the-secret-turbo-in-the-ring-slaying-porsche-919-evo-honeywell-garrett-dualboost-for-gasoline-turbocharger/

    With gas turbo engines, at WOT, the wastegate flow is typically like 30%-40% of total flow. On the 919, all that wastegate flow goes through a turbine which spins an electric generator, so basically waste heat recovery. With a track like Le Mans where the car is at WOT for long stretches, it generates a lot of energy!

    Reply
    1. Khiem Dinh says:
      March 28, 2019 at 7:48 pm

      Looks like Garrett just released an updated video and they have something now called DualBoost Twin-Flow.
      https://www.garrettmotion.com/news/video-center/video/dualboost-twin-flow/

      No clue on the turbo making it to production, but you can bug Mike Stoller about it. He posted his email in the comments section of my article on the DB:
      https://motoiq.com/the-secret-turbo-in-the-ring-slaying-porsche-919-evo-honeywell-garrett-dualboost-for-gasoline-turbocharger/

      With gas turbo engines, at WOT, the wastegate flow is typically like 30%-40% of total flow. On the 919, all that wastegate flow goes through a turbine which spins an electric generator, so basically waste heat recovery. With a track like Le Mans where the car is at WOT for long stretches, it generates a lot of energy!

      Reply
  5. joe says:
    March 28, 2019 at 4:41 am

    Looks like Garrett just released an updated video and they have something now called DualBoost Twin-Flow.
    https://www.garrettmotion.com/news/video-center/video/dualboost-twin-flow/

    No clue on the turbo making it to production, but you can bug Mike Stoller about it. He posted his email in the comments section of my article on the DB:
    https://motoiq.com/the-secret-turbo-in-the-ring-slaying-porsche-919-evo-honeywell-garrett-dualboost-for-gasoline-turbocharger/

    With gas turbo engines, at WOT, the wastegate flow is typically like 30%-40% of total flow. On the 919, all that wastegate flow goes through a turbine which spins an electric generator, so basically waste heat recovery. With a track like Le Mans where the car is at WOT for long stretches, it generates a lot of energy!

    Reply
    1. Khiem Dinh says:
      March 28, 2019 at 8:00 pm

      Looks like Garrett just released an updated video and they have something now called DualBoost Twin-Flow.
      https://www.garrettmotion.com/news/video-center/video/dualboost-twin-flow/

      No clue on the turbo making it to production, but you can bug Mike Stoller about it. He posted his email in the comments section of my article on the DB:
      https://motoiq.com/the-secret-turbo-in-the-ring-slaying-porsche-919-evo-honeywell-garrett-dualboost-for-gasoline-turbocharger/

      With gas turbo engines, at WOT, the wastegate flow is typically like 30%-40% of total flow. On the 919, all that wastegate flow goes through a turbine which spins an electric generator, so basically waste heat recovery. With a track like Le Mans where the car is at WOT for long stretches, it generates a lot of energy!

      Reply
  6. joe says:
    March 28, 2019 at 4:56 am

    Looks like Garrett just released an updated video and they have something now called DualBoost Twin-Flow.
    https://www.garrettmotion.com/news/video-center/video/dualboost-twin-flow/

    No clue on the turbo making it to production, but you can bug Mike Stoller about it. He posted his email in the comments section of my article on the DB:
    https://motoiq.com/the-secret-turbo-in-the-ring-slaying-porsche-919-evo-honeywell-garrett-dualboost-for-gasoline-turbocharger/

    With gas turbo engines, at WOT, the wastegate flow is typically like 30%-40% of total flow. On the 919, all that wastegate flow goes through a turbine which spins an electric generator, so basically waste heat recovery. With a track like Le Mans where the car is at WOT for long stretches, it generates a lot of energy!

    Reply
    1. Khiem Dinh says:
      March 28, 2019 at 8:12 pm

      Looks like Garrett just released an updated video and they have something now called DualBoost Twin-Flow.
      https://www.garrettmotion.com/news/video-center/video/dualboost-twin-flow/

      No clue on the turbo making it to production, but you can bug Mike Stoller about it. He posted his email in the comments section of my article on the DB:
      https://motoiq.com/the-secret-turbo-in-the-ring-slaying-porsche-919-evo-honeywell-garrett-dualboost-for-gasoline-turbocharger/

      With gas turbo engines, at WOT, the wastegate flow is typically like 30%-40% of total flow. On the 919, all that wastegate flow goes through a turbine which spins an electric generator, so basically waste heat recovery. With a track like Le Mans where the car is at WOT for long stretches, it generates a lot of energy!

      Reply
      1. joe says:
        April 1, 2019 at 6:44 am

        Looks like Garrett just released an updated video and they have something now called DualBoost Twin-Flow.
        https://www.garrettmotion.com/news/video-center/video/dualboost-twin-flow/

        No clue on the turbo making it to production, but you can bug Mike Stoller about it. He posted his email in the comments section of my article on the DB:
        https://motoiq.com/the-secret-turbo-in-the-ring-slaying-porsche-919-evo-honeywell-garrett-dualboost-for-gasoline-turbocharger/

        With gas turbo engines, at WOT, the wastegate flow is typically like 30%-40% of total flow. On the 919, all that wastegate flow goes through a turbine which spins an electric generator, so basically waste heat recovery. With a track like Le Mans where the car is at WOT for long stretches, it generates a lot of energy!

        Reply
  7. jeff says:
    April 21, 2019 at 2:32 pm

    Looks like Garrett just released an updated video and they have something now called DualBoost Twin-Flow.
    https://www.garrettmotion.com/news/video-center/video/dualboost-twin-flow/

    No clue on the turbo making it to production, but you can bug Mike Stoller about it. He posted his email in the comments section of my article on the DB:
    https://motoiq.com/the-secret-turbo-in-the-ring-slaying-porsche-919-evo-honeywell-garrett-dualboost-for-gasoline-turbocharger/

    With gas turbo engines, at WOT, the wastegate flow is typically like 30%-40% of total flow. On the 919, all that wastegate flow goes through a turbine which spins an electric generator, so basically waste heat recovery. With a track like Le Mans where the car is at WOT for long stretches, it generates a lot of energy!

    Reply
    1. Khiem Dinh says:
      April 22, 2019 at 8:19 pm

      Looks like Garrett just released an updated video and they have something now called DualBoost Twin-Flow.
      https://www.garrettmotion.com/news/video-center/video/dualboost-twin-flow/

      No clue on the turbo making it to production, but you can bug Mike Stoller about it. He posted his email in the comments section of my article on the DB:
      https://motoiq.com/the-secret-turbo-in-the-ring-slaying-porsche-919-evo-honeywell-garrett-dualboost-for-gasoline-turbocharger/

      With gas turbo engines, at WOT, the wastegate flow is typically like 30%-40% of total flow. On the 919, all that wastegate flow goes through a turbine which spins an electric generator, so basically waste heat recovery. With a track like Le Mans where the car is at WOT for long stretches, it generates a lot of energy!

      Reply
  8. jeff says:
    April 24, 2019 at 1:13 pm

    Looks like Garrett just released an updated video and they have something now called DualBoost Twin-Flow.
    https://www.garrettmotion.com/news/video-center/video/dualboost-twin-flow/

    No clue on the turbo making it to production, but you can bug Mike Stoller about it. He posted his email in the comments section of my article on the DB:
    https://motoiq.com/the-secret-turbo-in-the-ring-slaying-porsche-919-evo-honeywell-garrett-dualboost-for-gasoline-turbocharger/

    With gas turbo engines, at WOT, the wastegate flow is typically like 30%-40% of total flow. On the 919, all that wastegate flow goes through a turbine which spins an electric generator, so basically waste heat recovery. With a track like Le Mans where the car is at WOT for long stretches, it generates a lot of energy!

    Reply
  9. Nathan says:
    October 13, 2019 at 12:43 am

    Looks like Garrett just released an updated video and they have something now called DualBoost Twin-Flow.
    https://www.garrettmotion.com/news/video-center/video/dualboost-twin-flow/

    No clue on the turbo making it to production, but you can bug Mike Stoller about it. He posted his email in the comments section of my article on the DB:
    https://motoiq.com/the-secret-turbo-in-the-ring-slaying-porsche-919-evo-honeywell-garrett-dualboost-for-gasoline-turbocharger/

    With gas turbo engines, at WOT, the wastegate flow is typically like 30%-40% of total flow. On the 919, all that wastegate flow goes through a turbine which spins an electric generator, so basically waste heat recovery. With a track like Le Mans where the car is at WOT for long stretches, it generates a lot of energy!

    Reply
    1. Khiem Dinh says:
      October 13, 2019 at 9:19 am

      Looks like Garrett just released an updated video and they have something now called DualBoost Twin-Flow.
      https://www.garrettmotion.com/news/video-center/video/dualboost-twin-flow/

      No clue on the turbo making it to production, but you can bug Mike Stoller about it. He posted his email in the comments section of my article on the DB:
      https://motoiq.com/the-secret-turbo-in-the-ring-slaying-porsche-919-evo-honeywell-garrett-dualboost-for-gasoline-turbocharger/

      With gas turbo engines, at WOT, the wastegate flow is typically like 30%-40% of total flow. On the 919, all that wastegate flow goes through a turbine which spins an electric generator, so basically waste heat recovery. With a track like Le Mans where the car is at WOT for long stretches, it generates a lot of energy!

      Reply
    2. patrick says:
      September 28, 2023 at 10:02 am

      Looks like Garrett just released an updated video and they have something now called DualBoost Twin-Flow.
      https://www.garrettmotion.com/news/video-center/video/dualboost-twin-flow/

      No clue on the turbo making it to production, but you can bug Mike Stoller about it. He posted his email in the comments section of my article on the DB:
      https://motoiq.com/the-secret-turbo-in-the-ring-slaying-porsche-919-evo-honeywell-garrett-dualboost-for-gasoline-turbocharger/

      With gas turbo engines, at WOT, the wastegate flow is typically like 30%-40% of total flow. On the 919, all that wastegate flow goes through a turbine which spins an electric generator, so basically waste heat recovery. With a track like Le Mans where the car is at WOT for long stretches, it generates a lot of energy!

      Reply
  10. Richard Perry says:
    June 6, 2020 at 8:28 am

    Looks like Garrett just released an updated video and they have something now called DualBoost Twin-Flow.
    https://www.garrettmotion.com/news/video-center/video/dualboost-twin-flow/

    No clue on the turbo making it to production, but you can bug Mike Stoller about it. He posted his email in the comments section of my article on the DB:
    https://motoiq.com/the-secret-turbo-in-the-ring-slaying-porsche-919-evo-honeywell-garrett-dualboost-for-gasoline-turbocharger/

    With gas turbo engines, at WOT, the wastegate flow is typically like 30%-40% of total flow. On the 919, all that wastegate flow goes through a turbine which spins an electric generator, so basically waste heat recovery. With a track like Le Mans where the car is at WOT for long stretches, it generates a lot of energy!

    Reply
    1. Khiem Dinh says:
      June 21, 2020 at 6:37 pm

      Looks like Garrett just released an updated video and they have something now called DualBoost Twin-Flow.
      https://www.garrettmotion.com/news/video-center/video/dualboost-twin-flow/

      No clue on the turbo making it to production, but you can bug Mike Stoller about it. He posted his email in the comments section of my article on the DB:
      https://motoiq.com/the-secret-turbo-in-the-ring-slaying-porsche-919-evo-honeywell-garrett-dualboost-for-gasoline-turbocharger/

      With gas turbo engines, at WOT, the wastegate flow is typically like 30%-40% of total flow. On the 919, all that wastegate flow goes through a turbine which spins an electric generator, so basically waste heat recovery. With a track like Le Mans where the car is at WOT for long stretches, it generates a lot of energy!

      Reply
  11. Jon says:
    September 18, 2021 at 11:26 am

    Looks like Garrett just released an updated video and they have something now called DualBoost Twin-Flow.
    https://www.garrettmotion.com/news/video-center/video/dualboost-twin-flow/

    No clue on the turbo making it to production, but you can bug Mike Stoller about it. He posted his email in the comments section of my article on the DB:
    https://motoiq.com/the-secret-turbo-in-the-ring-slaying-porsche-919-evo-honeywell-garrett-dualboost-for-gasoline-turbocharger/

    With gas turbo engines, at WOT, the wastegate flow is typically like 30%-40% of total flow. On the 919, all that wastegate flow goes through a turbine which spins an electric generator, so basically waste heat recovery. With a track like Le Mans where the car is at WOT for long stretches, it generates a lot of energy!

    Reply
    1. Khiem Dinh says:
      September 18, 2021 at 3:46 pm

      Looks like Garrett just released an updated video and they have something now called DualBoost Twin-Flow.
      https://www.garrettmotion.com/news/video-center/video/dualboost-twin-flow/

      No clue on the turbo making it to production, but you can bug Mike Stoller about it. He posted his email in the comments section of my article on the DB:
      https://motoiq.com/the-secret-turbo-in-the-ring-slaying-porsche-919-evo-honeywell-garrett-dualboost-for-gasoline-turbocharger/

      With gas turbo engines, at WOT, the wastegate flow is typically like 30%-40% of total flow. On the 919, all that wastegate flow goes through a turbine which spins an electric generator, so basically waste heat recovery. With a track like Le Mans where the car is at WOT for long stretches, it generates a lot of energy!

      Reply
  12. patrick campbell says:
    September 28, 2023 at 9:59 am

    Looks like Garrett just released an updated video and they have something now called DualBoost Twin-Flow.
    https://www.garrettmotion.com/news/video-center/video/dualboost-twin-flow/

    No clue on the turbo making it to production, but you can bug Mike Stoller about it. He posted his email in the comments section of my article on the DB:
    https://motoiq.com/the-secret-turbo-in-the-ring-slaying-porsche-919-evo-honeywell-garrett-dualboost-for-gasoline-turbocharger/

    With gas turbo engines, at WOT, the wastegate flow is typically like 30%-40% of total flow. On the 919, all that wastegate flow goes through a turbine which spins an electric generator, so basically waste heat recovery. With a track like Le Mans where the car is at WOT for long stretches, it generates a lot of energy!

    Reply

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