[Mk2] [Turbo] my Monster Chargecooler build! FINISHED!!

[jimGTS]

its been a while coming, but after 7+years of mr2 turbo ownership, ive finally decided to give chargecooling a go, for no real reason other than to try something new.

ive had my hands on some decent intercoolers in the past, the Greddy and at present the Phoenix Power intercooler, regarded as one of the best side mount intercoolers, but time for a change as im running out of things to do on the car and a huge CC build seemed like a good idea.
thanks to JJ for answering alot of questions ive had, am sure there amybe more to come!

now i had considered the ST205 CC, but running a top mount turbo, this wasnt possible to fit without alot of work.
plus im not keen on the idea of it sitting above the engine and heard there only good for 350+hp anyway.
i also considered the Rogue radtek CC kit, but again, id have issues with fitment namely needing to pay out for more piping to fit my turbo setup, id also heard of a few cores failing and so spending near on £1000 on that didnt appeal. (plus it sits near the downpipe).
id also decided to stray away from the fiat Cinq rad and go for something alot meater as heard this rad is also not up to the task on mid power+ builds.

so ive gone for a huge 1000hp CC core, large pump and huge frozenboost pre rad

list of items

Gale force Marine 17ltr water pump
Ebay 1000hp chargecooler core 10"x9"x4.5"! AN fittings to hose
3inch pipework + hoses
10meters of 19mmID hose
half a dozen 90degree 19mm plastic bends for the hose
19mm ID rad cap adapter (for filling/bleeding)
26"x7"x2" thick frozenboost radiator with 19mm 3/4 hose/rad adapters
metal bars i need to custom make to hold rad in place

this system should do me wonders with any luck and be good enough no matter what power and boost i try and run through it!

**few issues already, the top straight rad/hose fitting wont fit due to the crash bar, so i need to find a 90degree bend one, basically a 1/2 npt brass to 90degree 3/4 hose fitting?? any ideas?? im really struggling!!!!!
other main concerns are how to hold the core in place in the bay, and how im going to route my turbo induction pipe!**

progress from the weekend.









routing of the hoses




struggling to find a way to neatly sort this section of undertray out!!?? :confused1:




rough position of rad







rough position of pump

[cvega666]

where are you mounting this core?

ps. thats a good pump, same here, no issues for a couple months now, just dont use the strainer that came with it - they crack!

[jimGTS]

hoping to mount it like this

[cvega666]

looks cool, it'd be interesting to see it when it's done. Do you have any links to the pre-rad and how are you mounting it ? I'm currently using a Fiat rad.

[jimGTS]

looks cool, it'd be interesting to see it when it's done. Do you have any links to the pre-rad and how are you mounting it ? I'm currently using a Fiat rad.

link

http://www.frozenboost.com/product_info ... 6e2a663712

and how im mounting it

[ashley]

Looking good Jim, looking forwards to seeing some before and after dyno plots

[craig]

Very cool build Jim, also be interested in before/after dyno plots

[jimGTS]

Cheers chaps
Just hope it doesn't take me weeks to put together!

[^Trickster^]

Looks like a nice setup, what kind of intake temps are people seeing in the UK with chargecoolers?

Graeme

[cvega666]

ST205CC, Fiat radiator, Gale Force 17l/min pump; Ambient about 20-25 C I see:

foot down for a while i see max about 50 deg c

Obviously shoots up to 60-70 when stationary in traffic.

Normal crusing is about 41-42 deg.

This is taken from one of the unused ports on the intake manifold past the throttle..

[.jambo.]

looks very nice mate keep up the good work

[^Trickster^]

Wow that's high!

I see between 30 and 36 normally st full boost, in very hot conditions I don't go over 40, cruising I can see under 30

I used to get 50 in standing traffic with a greedy sidemount years ago and that was worrying

Graeme [/b]

[Dale_V]

ST205CC, Fiat radiator, Gale Force 17l/min pump; Ambient about 20-25 C I see:

foot down for a while i see max about 50 deg c

Obviously shoots up to 60-70 when stationary in traffic.

Normal crusing is about 41-42 deg.

This is taken from one of the unused ports on the intake manifold past the throttle..

i certainly dont get that

rev3, st205 cc, st205 pump, fiat rad, 1.2bar

it'll do pull after pull after pull and NEVER go above 45deg C, even in the warm weather

on cruise about 30deg C

[Steve Horrocks]

Hmmm, that's higher than I'd thought. I used to get very similar to Graeme with my big ol' boot mount at 1.9bar!

I'm just fitting an st205 to my mk1.5 so I'll find a way of logging temps & find out what I get (stock rev1 engine at 14psi)

Sorry for thread hijack Jim! Your core looks very nice! Should be interesting to see what you get with it.

[jimGTS]

Wow that's high!

I see between 30 and 36 normally st full boost, in very hot conditions I don't go over 40, cruising I can see under 30

I used to get 50 in standing traffic with a greedy sidemount years ago and that was worrying

Graeme [/b]

I'm hoping for mid 30s on boost.
But I do have a high speed mat sensor, so will no dout read a much quicker and more accurate temp compared to a stock sensor as the stock mat is very slow to respond and I'd guess doesn't give accurate readings due to it's slow and laggy nature.

Core is massive, so I hope for some good readings and cold temps!

[cvega666]

hmm.. maybe i need to bleed the sucker.

where do you normally place your temp sensor ? I think mine might suffer from heat soak in the manifold there..

[jimGTS]

i would question where peoples sensors are before getting to worried.

and how there measuring it. (ie thermocouple, oem sensor, rait speed sensor, gm sensor), all of which may give different readings and respond slower or quicker than others.

[cvega666]

welllllllll........actually, I'm using a PC temp sensor, mounted in the intake plenum (one of the two ports normally blocked out). I know its most likely not accurate, so wondering how else can I monitor temperatures reliably.


btw, sorry for hijacking your thread, I'm happy to take the temp/sensor conversation somewhere else...

[Steve-O 2007]

looking good

struggling to find a way to neatly sort this section of undertray out!!??

I cant 100% remember but Im sure I cut away at the tray around the pipes to get the tray to fit better

[Super_red]

I am hoping to get 5 to connect my IAT sensor up this weekend, its supposed to be an uprated version of the stock item (i.e its got the same calibration but is not Toyota). Got it going to a megasquirt so I can log boost against inlet on a stock Rev2 for comparison to when I get my CC installed and then start uping the boost on a solenoid.

Interestingly I have a smaller 600bhp core but a bigger ST205 rad.