Heat Exchanger Upgrade

[Comin' in Hot]

A few weeks ago I scored a frozenboost model 101 really cheap on ebay. Since I had to work friday and couldnt go to New Hampshire, I decided to start my install.

Here are a few pictures of the heat exchanger itself:


http://i22.photobucket.com/albums/b335/Witman40/81DDC720-EC9C-4617-9B00-2598FBAEE762-2284-0000022760CD1F87.jpg

http://i22.photobucket.com/albums/b335/Witman40/CCBA8F39-F761-4FC4-A25E-D2ECE170712E-2284-00000227A0FBD513.jpg

I installed three(3) 7" fans on the back, here are some pictures after I made some brackets to hold them.

http://i22.photobucket.com/albums/b335/Witman40/FC211E30-C48E-44A9-BC13-3D0393E626AC-2284-00000227C35E0B6F.jpg

http://i22.photobucket.com/albums/b335/Witman40/0A86691E-D75D-49CF-BC21-95BE7AF904CF-2284-00000227B95EB304.jpg

Here it is installed. Notice how destroyed my old one was, its shaped like an "S".
http://i22.photobucket.com/albums/b335/Witman40/F4D823BA-92EC-444B-B872-24EAF53140FA-2284-00000227CC60E67A.jpg

http://i22.photobucket.com/albums/b335/Witman40/IMG_1509.jpg

http://i22.photobucket.com/albums/b335/Witman40/IMG_1507.jpg

http://i22.photobucket.com/albums/b335/Witman40/IMG_1508.jpg

[Comin' in Hot]

I ordered a dual fan manual relay kit from Jegs to power the fans and the intercooler pump. I wanted to be able to shut them off if I was ever sitting somewhere with the igniton turned to the accessory position. I installed the relays next to the battery. I also installed switches in the steering wheel kick panel.
http://i22.photobucket.com/albums/b335/Witman40/IMG_1500.jpg
http://i22.photobucket.com/albums/b335/Witman40/IMG_1505.jpg
http://i22.photobucket.com/albums/b335/Witman40/IMG_1503.jpg
http://i22.photobucket.com/albums/b335/Witman40/IMG_1510.jpg

Currently I'm about 95% done with the wiring and should start on the plumbing tomorrow night.

[RacerX]

Going to have to change your screen name to Comin' in Cool now. :lol:

Nice setup!

[boatmangc]

Where did you get the fans?

[RacerX]

Where did you get the fans?
I think: http://www.frozenboost.com/product_info.php?cPath=217&products_id=1003&osCsid=9bc54d9191452cc6fd318ef c0f2b8985

[DOOM]

Looks good.

[boatmangc]

I think: http://www.frozenboost.com/product_info.php?cPath=217&products_id=1003&osCsid=9bc54d9191452cc6fd318ef c0f2b8985

Those are 10"

[ImpalaSlayer]

looks good, i dig the lil fans

[Comin' in Hot]

The fans are from frozen boost and they are 7", they claim they are 1000 cfm each

[BODYMAN]

Looks like it should be a help. I like the thickness of the HE, switches also placed descretly I like.

[boatmangc]

The fans are from frozen boost and they are 7", they claim they are 1000 cfm each

I stand corrected. I gotta get me a couple of them.

[Mr. Man]

:eek:Had to work huh?........................;) :D

[hotford]

Yes thats the same one I went with for my Modfox coupe.........
its priced right...........

[blkZooM]

Did you happen to buy the car with that HE bracket or you made it? looks great.

[Comin' in Hot]

Did you happen to buy the car with that HE bracket or you made it? looks great.

I had to make the fan bracket and the top HE mounts, the bottom was from the original heat exchanger but I had to cut it in half, notch it in a couple of places to clear the fan screws, rebend it, and flip it upside down. So I guess you could say I made it..... It would have been just as easy to make it from scratch.

[MOTOWN]

Your setup looks great! thats the way it should be done! im sure the fans will help lower your IATs

[Comin' in Hot]

Thanks everyone for the compliments......I had a chance to work on the car for about an hour. I finished routing the harness to the switches and spliced it into the relay harness. I always cut the plastic shields off the connectors, crimp them, then give them a little extra crimp with vise grips, smear dialectic grease all over the connection then heat shrink them. I've never had one fail. I need to find some OEM style plugs so I could disconnect the fan harness and the water pump harness for repairs and I'll be done with the electrical. I also spent some time tonight planning my plumbing but I haven't decided to how that's going to go yet.

[MMBLUE]

Okay, I'm going to ask the dumb question; what would it matter if you painted the HE either a flat black or something unassuming? I got the" the paint between the cooling foils will lessened air flow" Besides that, what? And has anybody painted theirs? Sorry, don't mean to :hijack:. When I get my HE in I'd like to at least dust it with flat black. Keep'em guessing, ya know. Looks good BTW. Nice and neat.;)

[SC Cheesehead]

Okay, I'm going to ask the dumb question; what would it matter if you painted the HE either a flat black or something unassuming? I got the" the paint between the cooling foils will lessened air flow" Besides that, what? And has anybody painted theirs? Sorry, don't mean to :hijack:. When I get my HE in I'd like to at least dust it with flat black. Keep'em guessing, ya know. Looks good BTW. Nice and neat.;)

Have thought about painting mine, as it does stand out, but so far I've left it as-is.

[fastblackmerc]

Thanks everyone for the compliments......I had a change to work on the car for about an hour. I finished routing the harness to the switches and spliced it into the relay harness. I always cut the plastic shields off the connectors, crimp them, then give them a little extra crimp with vise grips, smear dialectic grease all over the connection then heat shrink them. I've never had one fail. I need to find some OEM style plugs so I could disconnect the fan harness and the water pump harness for repairs and I'll be done with the electrical. I also spent some time tonight planning my plumbing but I haven't decided to how that's going to go yet.

You should ALWAYS solder automotive electrical connections....

[justbob]

I had to make the fan bracket and the top HE mounts, the bottom was from the original heat exchanger but I had to cut it in half, notch it in a couple of places to clear the fan screws, rebend it, and flip it upside down. So I guess you could say I made it..... It would have been just as easy to make it from scratch.

Looks awesome man!


Sent from my iPhone using Tapatalk

[justbob]

Okay, I'm going to ask the dumb question; what would it matter if you painted the HE either a flat black or something unassuming? I got the" the paint between the cooling foils will lessened air flow" Besides that, what? And has anybody painted theirs? Sorry, don't mean to :hijack:. When I get my HE in I'd like to at least dust it with flat black. Keep'em guessing, ya know. Looks good BTW. Nice and neat.;)

I painted mine silver almost four years ago and i see the same average IAT's as every body else.


Sent from my iPhone using Tapatalk

[Comin' in Hot]

Theoretically the paint would act as an insulator, but the layer is so thin its effect is minimal.

[Comin' in Hot]

FBM I understand what you are saying about soldering, but I've never had one fail or corrode. Last week I opened up two splices on my 4x4 safari that I only take offloading and drive in the salt and snow and have never washed other than leaving it in the rain or an occasional stream crossing. The splices looked like I just made them and they have been there for 10 years.

[Blown3.8]

They make radiator black. Its a thinner paint.

http://www.eastwood.com/ew-radiator-black-12oz-satin-finish.html

[STEPS]

Looks good,
I want to put fans on mine FB but haven't got to it yet
Let me know how they work out

[Comin' in Hot]

I got the intercooler pump temporarily hooked up today and filled it with distiller water to see how it was going to run and check for leaks. My IAT gauge is actually my ETAC outside temp gauge, in thr past it would be at minimum 95 degrees even on the coldest day. It was 81 degrees today with moderate humidity according to weather.com at the time I tested it. I ran the car at idle for 30 minutes then took it for a 20 minute drive. My temp gauge never read over 82 degrees. I would have to say the new setup works. I'm still probably going to reroute my return line, maybe I'll get to it tomorrow.

Here is a pic from today
http://i22.photobucket.com/albums/b335/Witman40/11E9C5DC-0136-45AC-84C5-861E9E9B9916-656-000000D6FE496A83.jpg

[Comin' in Hot]

I had to modify the bumper reinforcement tonight to fit it back on the car. I might still cut it up some more if I decide to make a one-off bumper. I'm still undecided bc it might look like a ricer, but then again it might look like Trilogy 1. Anyway he are some pics

http://i22.photobucket.com/albums/b335/Witman40/925BD987-4CCF-476C-9B65-E0AD8EFF085E-776-0000006B88643B7A.jpg

I assure everyone my cut is straight, it's the bumper reinforcement that's wavy
http://i22.photobucket.com/albums/b335/Witman40/7F7A84E5-5617-4314-8999-7248FF0385A0-776-0000006B92ED57E1.jpg

[MOTOWN]

^^^^Thats the same thing we had to do to my bumper support to clear my intercooler!

Excellent work bud!

[Joe Walsh]

That bank of li'l fans looks great!

Are you running them all the time or are you running an adjustable thermostat to shut them off when not needed?
Could you wire them into the radiator fan circuit so that they do not run once the car is over 35-40 mph?

[Comin' in Hot]

Disclaimer: I'm not pointing fingers, but today was spent righting a lot of items that were installed half-ass by the original installer.

The pump was located on the passenger side with the previous setup and had no bracket, I moved it to the driver's side and made a simple bracket.

http://i22.photobucket.com/albums/b335/Witman40/1AE2DECD-5A3C-44F5-9D37-CB6F23FC7ADD-3130-00000309169A9382.jpg

http://i22.photobucket.com/albums/b335/Witman40/CDCCABFF-8143-4451-8B02-73174669674D-3130-000003090F4128FE.jpg

I had two huge problems with the previous setup.

First, the intercooler itself was not held in place with anything except the hoses and intake plumbing, causing the rubber hoses to pinch and chafe.

The second issue was that there was no way to fill the system because only fill point was the icebox under the air compressor tray/ behind the driver's side foglight in the most totally inaccessible place possible. I am not a rocket scientist, but I'm pretty sure there had to be air in the system. There was no way to purge the air from the intercooler because the fill was located about 10" under the intercooler.

I decided to delete the icebox because my heat exchanger is at least five times the of my intercooler and in my mind it acts as a cooler reservoir.

I used a combination of 1/2" pipe to make the bends in the tight corners and eliminate any chance of chafing and 3/4" hose in the areas where chafing is not an issue. I added a fill at the highest point no make sure I could bleed all the air out of the system. Here are some more pics of the finished product.

http://i22.photobucket.com/albums/b335/Witman40/8906949B-EAA9-4F04-895C-CCAD60276D6B-3130-00000308F2058734.jpg

http://i22.photobucket.com/albums/b335/Witman40/353CA94C-BE03-44AA-A6A3-40940724EEEE-3130-00000309206BE3AA.jpg

http://i22.photobucket.com/albums/b335/Witman40/5019D71A-9527-418D-B1F7-AF4F5ACBE3E2-3130-00000308E4556F0C.jpg

http://i22.photobucket.com/albums/b335/Witman40/232368E2-A9EF-4E9B-94C9-16DBB2E37B85-3130-000003090236EA11.jpg

I did not get to drive the car today, but I did let it idle for about 30 min. The IAT was only 10 degrees above the ambient air temp, I'm the past it would have been at least 30 degrees above at idle. Hopefully I'll get to drive it tomorrow!!!!

[RacerX]

I wondered about the IAT being linked to the EATC outdoor temp readout. I noticed it reads hotter since doing the Eaton swap and moving the IAT sensor and after being under boost, it jumps up a bit. Kinda cool, actually, since you can keep an eye on the temps. Nice work on the HE Comin' in Cool! :D