Not sure what you mean Tom ?

Not ambient .... more the IAT before a 3rd gear run vs IAT at end of run(WOT 2500-8000 @14psi)
. IAT starts off 2-3 degrees above ambient ...... so a total of 19-20 above ambient with the baffle.

Just talking about adding something to the inside of the intercooler where the air from the turbo enters the vertical passages or perhaps turbulators inside the vertical passages to drive up the heat transfer in the IC. This might better explain: How static mixers and turbulators can improve heat exchanger efficiency

Granted this might introduce risk of something breaking loose inside the IC and getting ingested by the motor which would almost certainly ruin your day.

Edit: the above is based on my assumption that the internal passages in of the IC have nothing in them. If there are fins inside the IC(like these https://vibrantperformance.com/catal...02c104c738020e), then my suggestion would be pointless.

One other alternative might be adding a water spray system to spray the exterior of the IC.

Well ..... I've done the vacuum cleaner test ... and managed to improve the uniformity of flow across the IC dramatically by filling in the gaps at sides of the baffle I had already made . Only problem is that the filler material is polypropylene which I just realised wont withstand the temps. Can't think how to fill the gaps any other way without cutting the tank off :(

See post 1794 and have a look at top corners of baffle to see the gaps I am talking about.

jb weld or epoxy filler? I would just cut the tank and get someone to reweld it.

The problem is ... the hole the baffle has to go through is smaller than the gap at the top of the intercooler (near the galleries). So I needed something i could flex through the hole that would straighten out once in there .

roofing silicone? rated to 150deg C

It's got to span approx 12mm and withstand 130C air hitting it at mach1 !

I have been working on my roof latley and 10yr old silicone is still bonded stronger than nails. I think it would work but?
the unknown is why you should cut and shut using aluminium. Surely it would only be $60 for someone to weld it up properly?

I hear ya on the welding RE ..... I was hoping to be able to try a few ideas before I did that though ...... to see what worked etc.

https://cimg5.ibsrv.net/gimg/www.rx8...af09912907.jpg
Vacuum cleaner setup
https://cimg4.ibsrv.net/gimg/www.rx8...2519bce8b9.jpg
Gappage

https://cimg8.ibsrv.net/gimg/www.rx8...1aed2714c2.jpg
mk2 gap filling method

what are you doing with the vacuum cleaner and ir sensor?

I blew through the IC and waited about 15 mins then measured the temp of each bar on the IC .
What I learned by doing that is that at low air flows both my old horizontal and the new vertical IC have very good flow distribution. I don't think high airflow follows the same pattern however.

The horizontal flow IC had a cruise IAT of 7-8 degrees over ambient whereas the vertical is down to 2-3 over ambient . I believe this is due to the fact that the vertical is getting most of it's area into good airflow whereas the horizontal one had over 1/3 it's frontal area blocked by the x-member.

So ..... this testing has led me to the conclusion that the end tank design isn't really a problem . I don't think there is anything I can do that will make a dramatic improvement .
I believe the internal fin design is a low resistance one and what is needed for this style of IC is a high resistance fin design like this:
https://cimg0.ibsrv.net/gimg/www.rx8...e84d225d77.jpg
See last pic in post 1811 for the difference

https://cimg3.ibsrv.net/gimg/www.rx8...5546c2e61e.png

IAT rise and RPM (at 13psi and 22C ambient) Vs Time . Note : 1/slight overun of temp. due to sensor reaction time 2/ recovery time after run

All this IC testing has led me to another idea to test .............. involving Water.meth injection . Just ordered some nozzles :)

I recall that you said you never had the results you anticipated from water/meth injection in the past, why don't you spray directly on the intercooler to reduce the heat soak on demand instead?
That way you'll never need to tune for the extra fuel injected and you'll get a significant reduction in temperatureas whenever you need it really.

​​​​👆 what he said??

i have something completely different in mind ,That I don't believe has been tried before .... details to come 😊

Wait, did you just copy and paste the above comment from "Brettus' Most Common Posts" notebook?

yeah but THIS TIME maybe I'm onto something :) ................... go to 0:11 in this add :

:yelrotflm

Nozzles in place ...just need to get hold of some methanol ..thinking a 50/50 mix will get best result for the effect I'm after.


https://cimg7.ibsrv.net/gimg/www.rx8...e96cb5eaec.jpg


My thinking is that this is the only runner that doesn't get cooling from fuel before it enters the engine , so if we cool this air we should get more power ........... fingers xd.

Only one nozzle?