Cheap Frount Mount Intercooler Options (from old site)
<TABLE border=0 cellSpacing=0 cellPadding=0 width="100%"><TBODY><TR vAlign=top><TD>Cheap Frount Mount Intercooler Options
contributed by Ian Simpson
Plenty has been said on this subject over the years...
So I've pasted a link here to a recent thread...
another thread...
and another...
the forge front mount kit...
If you have some good solid facts and / or data and photos then please send it to me for inclusion in this article.
The standard 5GTT core and it's standard replacements are 200mm x 200m x various mm thicknesses with a U bend half way. Straightened out this standard shape equates to:
400mm wide x 100mm high x 80mm thick = 5GTT standard cooler core, phase one or two.
400mm wide x 100mm high x 80mm thick = Pace standard replacement.
400mm wide x 100mm high x 110mm thick = K-tec or Forge standard replacement.(ô)
400mm wide x 100mm high x 130mm thick = GTTuning 'Double Capacity' standard replacement.(ô)
400mm wide x 100mm high x 96mm = 2wd Cossie cooler core dimensions.
460mm wide x 115mm high x 120mm = 4x4 Cossie cooler core dimensions.
500mm x 165mm x 60mm think = Forge FMINT104.(ô)
495mm x 180mm x 60mm think = Forge kit for 5GTT.(ô) (I'm told this size by an owner)
above are all core sizes.
(ô) I think I am correct in stating that these all use the Alutech extruded duct with the fins glued on.
The standard replacements mainly have the same number of ducts, 14. I have seen one with a turbo Technics sticker on it with 12 ducts for charge air. It was also about 100mm thick.
The cross sectional area of the ducts varies from make to make and this has a direct bearing on flow resistance, as well as cooling ability.
NOTE: NONE of them are double capacity
The standard coolers are both 80mm thick and twin cored.
The Pace 'double capacity' cooler is 80mm thick and twin cored.
The K-tec / forge 'double capacity' cooler is 110mm thick and twin cored (≈35% extra).
The GT Tuning 'double capacity' cooler is 130mm thick and twin cored (≈63% extra).
As far as ducting cross sectional area goes though the ≈ % extra I mentioned has some variables. On some the weld partly obscures all the duct inlets and exits so reducing area, but some have longer duct area front to back so that increases area. Reports are that the K-tec / forge work a bit better than the Pace. The main advantage of the GTTuning one might be it's reduction in charge air flow resistance due to the extra duct cross sectional area, but people over the years have claimed it doesn't cool so well due to cooling air not flowing through it's 130mm depth so well.
Cross sectional area of coolers end, for what that's worth:
Standard 80cm2
2WD Cossie 100cm2
Forge kit 108cm2
Cross sectional area of coolers front:
Standard 400cm2
2WD Cossie 400cm2
Forge kit 891cm2
Volume
Standard 3200cm3
2WD Cossie 4000cm3
Forge kit 5346cm3
The early Escort cooler is a bit odd looking as it has a small air/water cooler (charge cooler) at one end of the air/air intercooler.
Thanks to those who supplied photos and data and the helpful comments in the threads.
Ian S RTOC Profile https://www.rtoc.org/boards/images/bu...iend-small.gif
</TD><TD width=15></TD><TD width=200>https://www.rtoc.org/articles/i/autof...14_150x112.jpg
A not so cheap option
https://www.rtoc.org/articles/i/autof...14_150x112.jpg
Cossie 2wd adapted for 5GTT by Brizza
https://www.rtoc.org/articles/i/autof...14_150x112.jpg
2wd Cossie cooler fitted to McQueens 5GTT
https://www.rtoc.org/articles/i/autof...14_150x112.jpg
4wd Cossie cooler fitment by MC
https://www.rtoc.org/articles/i/autof...14_150x112.jpg
4wd Cossie cooler fitment by MC
https://www.rtoc.org/articles/i/autof...14_150x112.jpg
2wd Cossie cooler
https://www.rtoc.org/articles/i/autof...f14_150x73.jpg
Two coolers, top one is early Escort Cossie
https://www.rtoc.org/articles/i/autof...14_150x115.jpg
Cossie 2wd showing mods to fit the 5GTT
https://www.rtoc.org/articles/i/autof...f14_150x98.jpg
Cossie 2wd showing completed mods
https://www.rtoc.org/articles/i/autof...14_150x112.jpg
Cossie with pipes
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