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Re: Direct fit AWIC kits on the way.
Posted: Wed May 23, 2012 4:02 pm
by Turbo_Carl
Ubermeister wrote:I have read that the original Air-water-intercooler on 1st gen Legacy has an air flowrate of 230cfm.
My setup is: Forged conrods and pistons, E-manage ultimate, Td0516G big, 550CC injectors.
Running about 15Psi of boost, and i get a feeling that my intercooler is a bottleneck in my system. (getting increasing knock in high rpm/boost.
Since im testing E85 at the moment, im thinking about bypassing the intercooler, ie. plumb the turbo directly to the throttlebody, lower the boost and test if the car feels better to drive.
My plan is go get a nice chargecooler, add another electric waterpump in series with the stock one (one on each side of the system) + fit the largest possible radiator (since i dont have ac, i have more room..)
I live in Sweden, not very high temperatures, and its a daily driven car, so i think i will do without an watertank.
Hard to come by a nice fitting chargecooler (for resonable prices) in Europe, so i think i will buy from Votionspeed or Frozenboost.
I have a turbo car on E-85, and I would not recommend running it without an intercooler. While E-85 does defend against knock far better than "Premium" (91-93) Octane Gas. There is still some margin of error there. It's much more safe to wait until you can get a better flowing intercooler. Especially with your mods.
I am going to fix this turbo issue as soon as I can afford it. Should be in the next couple weeks, and then I will be able to complete this write up.
Re: Direct fit AWIC kits on the way.
Posted: Fri May 25, 2012 6:17 pm
by Legacy777
Ubermeister wrote:I have read that the original Air-water-intercooler on 1st gen Legacy has an air flowrate of 230cfm.
My setup is: Forged conrods and pistons, E-manage ultimate, Td0516G big, 550CC injectors.
Running about 15Psi of boost, and i get a feeling that my intercooler is a bottleneck in my system. (getting increasing knock in high rpm/boost.
Since im testing E85 at the moment, im thinking about bypassing the intercooler, ie. plumb the turbo directly to the throttlebody, lower the boost and test if the car feels better to drive.
My plan is go get a nice chargecooler, add another electric waterpump in series with the stock one (one on each side of the system) + fit the largest possible radiator (since i dont have ac, i have more room..)
I live in Sweden, not very high temperatures, and its a daily driven car, so i think i will do without an watertank.
Hard to come by a nice fitting chargecooler (for resonable prices) in Europe, so i think i will buy from Votionspeed or Frozenboost.
Do you have a way to check IAT's after the intercooler? If they are ok, then your intercooler shouldn't be the problem. The main thing the stock AWIC will add compared to a larger TMIC or FMIC is restriction which will just increase the amount of boost required the turbo has to push to get the same amount of air into the engine.
If you're experiencing knock, I'd suggest pulling some timing out and see if that helps.
Re: Direct fit AWIC kits on the way.
Posted: Tue May 29, 2012 11:36 am
by Ubermeister
Turbo_Carl: Sorry if i "hijacked" your thread, i just wanted some options and input
Legacy777: Thanks for the input, i cannot adjust my timing right now. (My E-manage Ultimate has som slight issues, i think i have to remove some cables. It fucks up the Ecu, according to a nice writeup on a GC-Install)
I have not installed IAT, so at this point i cannot check temperatures.
I have ordered the intercooler discussed earlier in this thread, from siliconeintakes/frozenboost.
Ordered a cheap new radiator for a vauxhall/opel, type 13 intercooler and the bosch pump, and will add my existing pump on the return-side of the system i think.
I will get back to you on the install, it's still a few weeks before i can start doing this mod.
Re: Direct fit AWIC kits on the way.
Posted: Tue May 29, 2012 4:14 pm
by Turbo_Carl
Ubermeister wrote:Turbo_Carl: Sorry if i "hijacked" your thread, i just wanted some options and input
Legacy777: Thanks for the input, i cannot adjust my timing right now. (My E-manage Ultimate has som slight issues, i think i have to remove some cables. It fucks up the Ecu, according to a nice writeup on a GC-Install)
I have not installed IAT, so at this point i cannot check temperatures.
I have ordered the intercooler discussed earlier in this thread, from siliconeintakes/frozenboost.
Ordered a cheap new radiator for a vauxhall/opel, type 13 intercooler and the bosch pump, and will add my existing pump on the return-side of the system i think.
I will get back to you on the install, it's still a few weeks before i can start doing this mod.
Don't worry man it's kinda an open discussion anyway.
Looking forward to see how the install turns out. You are ahead of me for sure. I still need to get my wastegate issue fixed.
Re: Direct fit AWIC kits on the way.
Posted: Sun Jun 10, 2012 8:43 am
by usliberty
Sweet thread . My JDM phase 1 EJ20G came AWIC and I traded it for some cash+ a TMIC. Wish I had kept it now because I ended up going FMIC. I think its a great idea, especially if you make the reservoir with an opening big enough to throw a bunch of ice in if you want to.
Re: Direct fit AWIC kits on the way.
Posted: Wed Jul 04, 2012 6:04 pm
by Ubermeister
Turbo_Carl: Fixed your turbo yet?
Just as i was ready to mount the beefier intercooler, i think i blew a headgasket..
Could be from knocking or cheap noname mls headgaskets..
Anyway, i can now recheck my lifters, i dont like that knocking sound from them.
Re: Direct fit AWIC kits on the way.
Posted: Tue Aug 21, 2012 3:10 am
by kimokalihi
Comin up on 3 months with no updates. You get this kit figured out yet or did you give up?
Re: Direct fit AWIC kits on the way.
Posted: Tue Aug 21, 2012 3:36 am
by alexandermf
I see Carl every once in a while and saw him last Friday, he is extremely close to finishing and progressing
Sent from your bathroom closet
Re: Direct fit AWIC kits on the way.
Posted: Tue Aug 21, 2012 3:51 am
by kimokalihi
Oh cool that's good.
Re: Direct fit AWIC kits on the way.
Posted: Mon Aug 27, 2012 7:37 am
by Turbo_Carl
Sorry I have not thrown out an update in a while. I'm not one to keep stringing people along if I have not made any progress. I semi fixed my wastegate issue. It holds 10psi of boost, but make a horrible noise. I bought another VF11 and I believe that the wastegate door itself is warped on the one currently on my car.
I am buying this my next paycheck.
http://www.maperformance.com/grimmspeed ... -tube.html and going with an external wastegate.
This will have no effect on the installation instructions because I am sticking with the VF11 until the video is done.
I am very close now, and I will try to keep you all updated.
I have to go TDY to California for a few weeks in september, and should have enough money saved up to finish the project when I return.
Re: Direct fit AWIC kits on the way.
Posted: Sat Sep 08, 2012 6:23 pm
by ride_child
stoked on this! eagerly awaiting the video!
Re: Direct fit AWIC kits on the way.
Posted: Sat Sep 08, 2012 7:42 pm
by kimokalihi
So you're using a vf11 with your awic setup? I'm going to have to make one of those intercoolers fit my td05. I wish I could test fit everything in person like you.
Re: Direct fit AWIC kits on the way.
Posted: Sat Sep 08, 2012 9:05 pm
by ride_child
pardon the newbiness but is the compressor housing/outlet that much bigger/different be tween the vf11 and the td05 that it would take a different setup? or is it that it has a higher flow rate or am i completely off base? haha only because im running the stock vf11 and plan to one day upgrade to both a td05 and an awic.
Re: Direct fit AWIC kits on the way.
Posted: Sun Sep 09, 2012 9:33 pm
by Legacy777
The compressor outlet on the vf11 is clocked at about 45 degrees above the horizontal axis. The td05's compressor outlet is at the horizontal. This difference necesitates changing how the piping is hooked up.
Re: Direct fit AWIC kits on the way.
Posted: Sun Sep 09, 2012 11:17 pm
by ride_child
Gotcha, thanks for the info Josh!
Re: Direct fit AWIC kits on the way.
Posted: Mon Sep 10, 2012 5:34 pm
by Legacy777
You're welcome.
Re: Direct fit AWIC kits on the way.
Posted: Fri Sep 21, 2012 8:46 am
by Turbo_Carl
Buying all the parts tomorrow! Let's do this!
If I can get the rest of my buddies together Saturday or Sunday I should be able to release a video this weekend.
Either way, the video will be done very shortly.
kimokalihi, the instructions should be the same with the Td05 you probably would just need a bigger turbo outlet silicone elbow to make it work.
Re: Direct fit AWIC kits on the way.
Posted: Fri Sep 21, 2012 8:51 am
by ride_child
So excited, I want one for my car!
Re: Direct fit AWIC kits on the way.
Posted: Fri Sep 21, 2012 4:28 pm
by kimokalihi
I'm excited to see this.
Re: Direct fit AWIC kits on the way.
Posted: Mon Sep 24, 2012 7:11 am
by Turbo_Carl
Almost done!
Need to run water lines, but the car runs great!
Here is a teaser video until I finish the rest.
http://www.youtube.com/watch?v=Wu35q7LN ... e=youtu.be
btw... the video is only going to be problems or questions you might run into, and not 2 hours of me unscrewing stuff lol.
Re: Direct fit AWIC kits on the way.
Posted: Mon Sep 24, 2012 7:20 am
by kimokalihi
Very nice. I'm glad you're still with us. I was starting to think I would be pioneering this project myself. I just ordered a nifty little setup to monitor intake temps before and after the intercooler so I'm going to get that set up on my WRX TMIC first to see if it's even functioning and then I might mess around with ducting to help it out or just go straight to an AWIC setup and again I will set it up to monitor the efficiency of the AWIC.
Re: Direct fit AWIC kits on the way.
Posted: Mon Sep 24, 2012 7:28 am
by Turbo_Carl
Here is a picture of what I have done so far.
A/C is going to be a problem.
You can surely keep A/C, but that is going to require a custom heat exchanger and or a/c condenser. Both of which I did not have time to get made or find. The Intercooler fits fine with all the A/C lines in tact, but that condenser is a bitch! My A/C didn't work, so I really wanted to remove it. The rest of my instructions will be perfect though.
Re: Direct fit AWIC kits on the way.
Posted: Mon Sep 24, 2012 7:33 am
by kimokalihi
What was the cost of everything? I could look....but it would be nice to just have that info here. I like the video and you should make more of the rest of the install. Did you have to cut anything to mount that heat exhanger in the bumper?
Re: Direct fit AWIC kits on the way.
Posted: Mon Sep 24, 2012 7:46 am
by ride_child
what if you take out the ac system and use the exchanger from that as the one for the awic? just thinking...
Re: Direct fit AWIC kits on the way.
Posted: Mon Sep 24, 2012 7:48 am
by kimokalihi
Hmm. I have no idea if that would work well enough or not. It's pretty damn thin, I don't know the thickness of a typical heat exchanger. My AC condensor weighed almost nothing.