Intercooled Manifolding

Posted by T.O.O. on July 15, 1998 at 22:32:53:

The pictures on the In Box of the HYBRID site are of the original "B" casting. We've been working very long hours now in an effort to cool the temps. as the boost goes from 17 - 24 psi. After a lot of prototypes, we've succeeded in construction of what we call a "membrane" cooling element that resides in the plenum chamber.
It is also very effective at directing air flow with no losses, and therefore makes better power when not cooling.
Now, understand this. The intercooler has a coolant circulated through the element in the manifold plenum, so it has a small "tank"..1ltr. and a small "radiator" the size of a typical oil cooler, so it doesn't take a lot of space.
I will not discuss the coolant we circulate at this time, as there are currently a lot of people attempting to do the same thing, and if they're going to find out how we do it, they're going to have to purchase a blower kit.
The "membrane" allows us to use it in manifolds that are already nearing completition. The last thing I want to happen, is for early kit purchasers to think that their system is obsolete.
This is a very real concern to me, as we've already added so many new parts to the package, had we sold some 4 months ago, those customers would likely be somewhat pissed. So the problem is how to keep pushing for more performance in the future without offending current customers?? We will certainly attempt to make any new components so they can be added to existing kits, but I really don't know any other way to do it. It's like some of my stereo components, about every other year, someone comes out with an improved D/A converter, but I can send mine in and pay to have it up-dated.
If any of you have any thoughts on this subject, please post them, as technology doesn't stand still, and I don't want customers to feel like they just bought a new computer, and now it's obsolete. Help me if you have any thoughts. Thanks,.............................T.O.O. ...................

Re: You're All Correct

Posted by T.O.O. on July 17, 1998 at 19:24:30:
In Reply to: Re: Laws of Thermodynamics posted by body on July 17, 1998 at 16:59:11:

First, the laws of thermodynamics are correct on that in many instances you can use more power to cool the mixture than the power you gain = net loss. You can do the same thing with a blower. If the engine makes 60 more HP, but requires an equal power # to drive the blower, you make the same # as before, but your performance will be degraded due to the additional mass the engine must drive.
We're using a very efficient electric pump, which places a minimal draw on the charging system...about the same as a 100 watt amp. The refrigeriant is a new EPA friendly coolant with many unique features. One of which is the small size of the coolant to air "radiator", and the other is the small return tank prior to re-entry to the in-plenum element.
The in plenum element option was chosen because addition of a plate with sufficient cooling surface area would make the O.A. package too large. New manufacturing technologies are allowing us to make these units "membrane configured" so there is no flow loss, but a 50% reduction in temps. The height or length of the cooling element "fins" are 2", and we're working as hard as possible to make necessary changes in previously "frozen" designs so they can accept the unit. I don't want customers to feel that they were ripped by buying an early piece, which is now "out-dated". It's a problem that concerns me deeply, as we're used to continued development on all's how we stay ahead of the competition and continue to offer leading edge designs in all our endeavors.
I appreciate all your comments and thoughts relative to the subject. It's a good feeling that I get when reading your research and opinions. This board has come a long way, and it's great to see that every now and then old T.O.O. can stirr the juices some.
As always, I appreciate your ideas. You guys are the reason the blower box keeps growing in size, and costing me more on each one we sell.
Thanks,.............................T.O.O. ..................................

Turbo GSR And Self Contained Intercoolers

Posted by T.O.O. on July 18, 1998 at 18:45:55:

If the actual cooling element is inside the manifold, the intercooler is "contained " within the dig??
The fact that the coolant is circulated does not make the cooling process take place anywhere except the plenum.
Now, you tell me how many intercooler elements are actually part of the internal plenum on a manifold, and while you're at it, find one that can provide a 50% reduction in temp. with the coolant lines .625 ID. and a coolant to air radiator of 5''x 10 ''x 1.5". and a tank of less than a quart capacity.........sure sounds like all the others on the market to me!!!..............................THE OLD ONE......................