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Old 02-03-2008, 12:42 PM   #1
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Default Project intercooled SLE: Project updated 2/28/08

I've created a monster. Well I have been planning and working this one for two or three months now over the winter months and it has finally come together. Project intercooled Bonneville SLE. First came the first 00+ supercharged SLE, now comes the first intercooled SLE and one of only a half a handful of intercooled Bonnevilles in exsistance. This project possed a few obsticals and challanges coming together. The first was making my own modified fuel rails with upgraded AN fuel lines installed. The second was where to stick the radiator/heat exchanger and to have an efficient one in a 00+ Bonneville since there is about an inch of room to work with. I tackled that by finding and installing the radiator that is used on the racing version of the intercooled corvette C6. It is a double pass system designed to be small and light weight but very efficient. Hey, if it is good enough for the corvette racing team then it is good enough for me. Plus I got it for a steal over what Intense wanted for their slim design radiator. Third issue was a little innovation by myself. I am using the SSIC from ZZP as the intercooler. Well that wasn't good enough for me to go with the norm and just bolt it up right? So I've created a prototype intercooler spacer that works much like the idea of the TB spacer to keep the engine heat from seeping up through the stacked up aluminum and creating more heat. It raises the blower another inch in addition to the inch of the SSIC and then with the gaskets and everything it becomes equivalent to the size of the stage II IC. This is probably not be as efficient as the full stage II IC for obvious reasons, but I believe that it will be much more efficient then the SSIC by itself. Early testing indicates that the blower temps are significantly cooler after driving around for several hours and then immediately testing temperature then without the spacer installed. For example I made a trip to downtown Boise and back wich is about a 30 mile round trip and without any cooldown time at all the blower was barely warm to the touch. Almost cold even. It was amazing really! Further testing and trial at the track will tell of its abilities and durability as well. I'm excited. Fourth was a prototype ice box for track time that was to be installed inside the fender well of the bumper. That install didn't go so well and the box kind of came to a braking point of no return during install. I may redesign it and try again, but time will tell if I get excited about it again after the flop. However I have created a specific ring of tubing that will allow me to place a bag of ice in the middle at the track for easy cooling of the intercooler fluid system. It should work well, but again only time will tell. If anything it increased my fluid capacity by about a gallon. Another issues was hood clearance of the Bonneville. With the stack that I have is exactly perfect with only a small modification to the hood in two places and having to turn the 85mm MAF down to clear the hood. I was a little nervous about that, but it went in there with a little "persuation." Stage III will NOT fit in a Bonneville without major hood modification! The finally step was to wire the pump with a relay and get that going. It wasn't too hard after I figured out what wire went where. I am also going to install an override switch for track time when the car is off, but that will take about 5 minutes when I get around to it. In the mean time I am going to be doing some small tuning until the weather gets better and then some major stuff when it warms up more and we start getting some track times. Hopefully with all this I will reach 12'* this year as a goal on a stock cam and Gen III blower with fat ole Bonneville.








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Old 02-03-2008, 12:46 PM   #2
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The REAL workis hidden. Let'* see your SC outlet machining and LIM machining. That'* what anyone wanting to do this will be interested in. (obvious o me you didn't buy a machined housing, unless you found the time to re-polish again).
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Old 02-03-2008, 12:54 PM   #3
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That blower looks amazing. Will be interested to see how your times come out.
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Old 02-03-2008, 12:57 PM   #4
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Quote:
Originally Posted by willwren
The REAL workis hidden. Let'* see your SC outlet machining and LIM machining. That'* what anyone wanting to do this will be interested in. (obvious o me you didn't buy a machined housing, unless you found the time to re-polish again).
x2
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Old 02-03-2008, 12:59 PM   #5
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Oh yes, you know I port my own stuff. Here you go.



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Old 02-03-2008, 03:10 PM   #6
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Looks great. Keep up the good work.
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Old 02-03-2008, 03:14 PM   #7
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I'll be curious about your thermal isolation results. At WOT, the Supercharger itself (regardless of intercooler) will create more heat in the inlet of the SC than the LIM would normally see. In that regard, there are times you'd not want it thermally isolated.

For daily driving it may benefit you though. Other than in summer heat perhaps. This'll be a good thing to compare come WCBF. We have alot of new superchargers and intercoolers coming about, so we can actually do some basic comparisons in temperatures.
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Old 02-03-2008, 03:20 PM   #8
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Slick lookin' setup, Jared!
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Old 02-06-2008, 06:57 PM   #9
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Quote:
Originally Posted by willwren
I'll be curious about your thermal isolation results. ...... We have alot of new superchargers and intercoolers coming about, so we can actually do some basic comparisons in temperatures.
I am pretty excited about it to see if it helps. I took it on a long trip this weekend about 3 hours straight without shutting her down and when I got there and popped the hood I put my hand on the blower and it was absolutely cold. It was a little freaky actually. I wasn't in boost very much, but that will come with track testing. It will be exciting to see comparisons in summer temps when they come along, very agreed.
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Old 02-06-2008, 07:00 PM   #10
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VERY impressive!
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