Air to
Air:
For air to air intercoolers
there are two main styles:
1. One has the heat exchanger at the
front of the car and long pipes that bring the air from the turbo up to
the front, thru the intercooler, and back to the motor. This piping
can add 2-3 psi pressure drop. This extra
pressure drop requires the turbo to work harder to overcome this pressure
loss and therefore the air will be still hotter. Two other drawbacks are
that the intercooler will not really help much if the car is stationary
and the amount of piping that will be filling the engine compartment.
2. The other option is
to put the intercooler on top of the engine and add hood scoops/ducting
to provide the air. This is what was done by Ford on the Mustang
SVO's and the 1987/1988 Thunderbird Turbocoupe's. This helps with
the pressure drop problem, but the intercooler is now placed on top of
the engine, right above the exhaust manifold. This results in hot
air rising up from the exhaust manifold and heating the intercooler when
the car is standing still. However, this has got to be the cheapest
and simplest set-up.
Air to Water:
The air/water intercooler
is more complicated but should work much better. This system works
by adding a separate cooling water circuit. (You don't want
to use the engine coolant because it is too hot.) The cooling water
will pass through the cooling side of the intercooler (in place of the
air) then it will pass through another heat exchanger at the front of the
car, to reject the heat that it picked up from the turbocharged air.
In my opinion, this was the best of both worlds.
The system had the short intake path of the Mustang SVO arrangement, resulting
in a very minor pressure drop in the intake piping. It also provides
improved heat transfer since water conducts heats so much better than air.
(think about cooling a hot spoon by blowing on it, or sticking it under
the faucet.) Because the intercooler is surrounded by a water jacket,
it is also less susceptable to the chimney effect of being located directly
above the exhaust manifold. The drawbacks of this system include
added complexity and expense.
With these factors in mind, my feel that I
have built an affordable high-performance air/water intercooler for the
Merkur.