VCP Air to Water Intercooler kit

[Wayne Presley]

The kit is finalized and ready for orders. Comes complete with all the T-bolt clamps, Bosch water pump, large heat exchanger, fittings, hose clamps, BOV/BPV, coolant hose and intercooler core. The AWIC will give lower intake temps than the stock air to air intercooler. $1400 plus shipping.









IC core bleed valve installed. Allows you to make sure there is no trapped air in the IC core. Simply run the pump and loossen bleeder until coolant comes out then close bleeder. Top off radiator.



Tool less bleed valve option (Add $10)

[Santiago]

That's a solid deal. I took some time to pretty meticulously spec out a complete system very similar to this and didn't come up with much of a savings. Plus, to do it I'd still have to get the bit of custom work done on the tubes. Save the time. Get the kit. From Wayne. With your money.

(Sorry I'm on a JSP kick today.) =)

Best,
-j

[07FIREBLADE]

Looking at the pics. Where is the bov mounted. And is there an option for the dual exchangers like on eriks

[Wayne Presley]

The BOV is an option and can be mounted on the tube underneath or on the end of the IC core. Dual heat exchangers would be available at additional cost and you would have to fabricate the mounts.

[bompus]

Looks beautiful. I already have this on order along with some other goodies. Great job Wayne.

[K3LAG]

Wayne,
It looks like you redesigned the position and mounting of the intercooler to take up less space. Does it leave room for a trunk now?

Larry

[Wayne Presley]

It allows for the trunk now, one of the reasons for the redesign over what's in my car.

[K3LAG]

That makes it really tempting. It looks like the orange stickers and plumbing might even almost match my car ;-)

Larry

[Wayne Presley]

Well the sticker is orange but the silicone is red, the camera sucks at red variations. I took pics of the floor mats and the near one face on looks yellow and the other side off center looks the correct orange.

[07FIREBLADE]

Wayne for this setup is there no fan for the heat exchanger. By the looks of it there isn't. Is it just setup to use the radiator fan to creat suction through both exchangers? And is the pump the Bosch pump that comes on the cobras?

[Wayne Presley]

You can put side skirts between the heat exchanger and radiator to use the radiator fans. I don't think they are needed as there is no significant intake heating while the car is stationary, there is plenty of coolant volume and as soon as the car gets rolling there will be plenty of air flow. We run a 20% smaller heat exchanger on the SC Lotus and IC water temps after a 30 minute race average 115° F with no fans. It is the same pump that is on the SVT Cobra and Lightning F-150's.

[nkw8181]

Dang you Wayne my budget keeps going up because of people like making awesome things that I "need". I'm just prioritizing what I need first. Keep up the good work. Oh I really like that you made it so we can can have a trunk (even if it is small).

[07FIREBLADE]

Trunk will be the same size as if you were using the stock tmic. Thanks for the info on the awic. When budget permits I'll be in touch. Just wanted to do my research.

[Xusia]

Yeah. I haven't yet decided what to do as far as an intercooler solution, and since this allows for a trunk and requires no engine compartment airflow, I just might spring for it.

[Wayne Presley]

Here are pics of the plumb back option TurboSmart bypass valve.






Here is the straight blow off TurboSmart valve version (available blue and black).




Either valve is a $200 option to the AWIC kit price.

[Doowop]

Wayne,

any numbers on the temp difference between that setup and a regular IC? what about weight? thanks

[Wayne Presley]

In cruise driving the stock air to air was showing 35°F over ambient, with the AWIC blasting around it was showing 8°F above. Huge difference in cooling. I'd say it weighs 18-20 lbs more than the stock 02-05 IC.

[Santiago]

Wayne, is a reservoir included as well? I didn't see it in the list of what's included but I thought you were originally offering it in the kit and you mentioned coolant volume, so I thought I'd ask.

Even if it is not included, any thoughts on what sort of performance level/demands would make one appealing in our application? For ex: typical use of an 818R vs 818S?

Thanks!

Best,
-j

[Doowop]

Wayne, could you be a little more details on how everything mounts, where the pump goes, what it looks like? Do you have pictures of the full install? Where do you run the hoses to the front heat exchanger? thanks

[Wayne Presley]

The pump mounts up front by the battery and is a Bosch pump. The hoses run down the side of the car by the coolant tubes and go to the drivers side of the heat exchanger. The pic in the first post shows the mounting of the heat exchanger and the outlet ports.

[Wayne Presley]

Wayne, is a reservoir included as well? I didn't see it in the list of what's included but I thought you were originally offering it in the kit and you mentioned coolant volume, so I thought I'd ask.

Even if it is not included, any thoughts on what sort of performance level/demands would make one appealing in our application? For ex: typical use of an 818R vs 818S?

Thanks!

Best,
-j

It works so much better than the stock air to air even on a base 2.0 build. Add HP and that adds heat to the charge and it becomes even more important. I changed heat exchangers which deleted the need for a reservoir since the volume doubled and has a radiator cap.

[Hindsight]

I'd say it weighs 18-20 lbs more than the stock 02-05 IC.

Wayne, is 18-20lbs the difference between the stock IC and this IC only, or does it include the weight of the front mounted heat exchanger + hoses to it and pump and water? How many gallons does it hold?

Thanks

[Wayne Presley]

I would say it holds about 2 gallons of coolant. I would say the IC themselves weigh about the same and the extra weight is in the HE, pump and hoses.

[Hindsight]

Nice, 20lbs is a very, very small price to pay for the increase in cooling performance, I feel.

[Frank818]

Looks like Wayne has updated his website! Pretty cool! It's animated now!

http://www.verycoolparts.com/

[bompus]

Hey Wayne,

Would you be able to provide some install instructions for all those that may be interested? I'm curious because I've seen others use a separate reservoir, but not sure if that is required or not. A step-by-step would make the install easy to understand for all and might even lead to more sales

[Wayne Presley]

Here is the heat exchanger mounting
Put fittings and mounts on as shown with supplied hardware, leave mounts loose.



Place the HE in front of the radiator with the brackets using supplied Rivnuts and brackets.







Mount the IC coolant pump behind the battery with supplied mount



run hoses to the rear, clamp along the frame

[Wayne Presley]

Loosely bolts in both front IC mounts on the block. Put the 45° 2" silicone hose on the outlet of turbo with supplied T bolt clamp and insert BOV/BPV pipe, connect BPV hose to BPV if applicable. Put the 45° 2.75 to 3" adapter on the throttle body. Put the coolant hose fittings on the IC, 90° on drivers side. Install IC using the front mounts already in place, and loosely place Tbolt clamps on the throttle body silicone.



Install rear mount, 02-04 mount shown.



Put the 90° silicone on the BOV/BPV tube, use the 6" aluminum coupler to the 90° adapter to the IC.

[nkw8181]

nice! can't pull the trigger on this yet but working on the budget to me it so

[bompus]

Wayne, do you recommend an overflow tank in front and back then? If so, do you just hook lines up from both the radiator and heat exchanger to the front overflow?

[Frank818]

The hoses run down the side of the car by the coolant tubes and go to the drivers side of the heat exchanger.

What I was looking for, couldn't tell if there was enough space by the sides as I don't have mounted the body panels yet.

[Wayne Presley]

Wayne, do you recommend an overflow tank in front and back then? If so, do you just hook lines up from both the radiator and heat exchanger to the front overflow?

The HE will need a small overflow. For the engine cooling system, I much prefer a single coolant recovery tank in the back. Put a higher pressure cap up front and cap/plug the recovery tube.

What I was looking for, couldn't tell if there was enough space by the sides as I don't have mounted the body panels yet.

There is room down the sides as I've had the sides on this car after installation of the system.

[bbjones121]

Does this protrude into trunk space much? If so, is there any other configuration that wouldn't?

[Wayne Presley]

Does this protrude into trunk space much? If so, is there any other configuration that wouldn't?

It does not intrude into the trunk space

[bbjones121]

Awesome! Any photos of top view showing how far back it goes? Or side.

[Wayne Presley]

The trunk opening is just over 6" past the cross brace, the intercooler extends just under 6" past brace.

[bbjones121]

thank you for all the pic.

[Frank818]

Here is the heat exchanger mounting

What are the size specs of this HE again? I see it's the one metalmaker got, I look for something similar to that. It's nice that it has already the mounts, so if I like the size and price, I might be a buyer. For the HE alone, though.

[Wayne Presley]

I was on the dyno today with an 818 with my AWIC on it and it works awesome! It was hot here today, 94°F and after 20 pulls on the dyno, the manifold air temp went up from 94 to 102°. That's pull after pull after pull. The most temp increase during any single run was 1°.

[Sgt.Gator]

And no Dyno results? Curiosity !