Home made intercooler.

[impaladave]

Has anyone designed and built their own intercooler?I am installing it on my 96 Impala, but the kit I have is the Vortech kit from the LT1 corvette. It has some clearance issues from the outlet of the SC to the inlet pipe of the throttle body.
I own a manufacturing company and can fab up the parts, but want to know if there are any design issues I should look out for.I'll take any suggestions.

Thanks,
Dave

[Fire67]

Im not too up on actual intercooler design, but I know certain designs flow better than others. Expect a noticeable gauge drop in psi but a definite increase in power... Then change the pulley to get the same boost back
I would match the intercooler inlet/outlet diameters to the outlet diameter of the blower for a minimum tubing size.
With the intercooler, the core needs to flow the air from your blower with minimal pressure drop. And be able to cool the air efficiently.
Show us some pics of your engine compartment how it is plumbed now. Specifically some pics of the areas where there are clearance issues.

[impaladave]

Cool, I'll try to get some pics today.

Thanks,
Dave

[impaladave]

Here is a pic of my system( the link below). No room for the intercooler, unless I change the intake/bypass valve setup. This would allow me to come in from a different angle.
Has anyone used a PWR barrel intercooler? Seems like a nice setup, and if I mount the tank inside the car, I can run the AC and get the temp nice and cool ;D
( just a thought)
Wouldn't Alky injection be the cheapest, easiest, coolest way out with the least pressure drop?

www.vortechsuperchargers.com/products/yourcar/94-96corvette.html

I'll take any suggestions,

Dave

[Fire67]

Keep in mind that you can rotate the head unit to point the discharge where you want it... I can see that the way it points now is not gonna work at all.
No luck getting pics of your installed kit in your car?
Im not sure what you actually have for room, but Id try to point the discharge towards the passenger side. Then plumb it to a front-mount and back to the TB via the drivers side.

Yes Alky would be the cheapest and easiest way out... But if you tune for max power with Alky and run out, your motor's toast.

[impaladave]

Can't get any pics cause the car is at DEZ Racing( Massachusetts) getting a fuel pump, intercooler, and a dyno tune( SWEET!!).
Anyone else been to see Mike or Don (slowhawk)? Great, and knowledgable guys. I hope I can get 500RWHP@ 8-9 psi with the fuel and cooling all set, it's also 50 degrees around hear which is great for building power.

Dave

[1bad2k2ta]

impaladave said:

Can't get any pics cause the car is at DEZ Racing( Massachusetts) getting a fuel pump, intercooler, and a dyno tune( SWEET!!).
Anyone else been to see Mike or Don (slowhawk)? Great, and knowledgable guys. I hope I can get 500RWHP@ 8-9 psi with the fuel and cooling all set, it's also 50 degrees around hear which is great for building power.

Dave

That's great news, Dave. I look forward to seeing what numbers you put down. Post up a pic of your dyno sheet. I am familiar with Slowhawk from the ls1tech forced induction forum.

[impaladave]

I can't wait, but racing is just about over in these parts. Don is a cool guy, and knows his stuff with the LT1 edit. I'll post the sheets as soon as possible.

Dave