Upon receiving the aftercooler kit from Sonny I naturally looked for ways to add as much reliability to it as I could. After some thought I went a little further and decided to see if I could get a little more core inside the JRSC. Sonny was nice enough to point me in the direction of Bell intercoolers.

One worry I had with adding more core was whether or not it would negtively effect the amount of air coming into the blower by creating a constriction in there. After working with Bell intercoolers and getting advice from T1 racing the cooling gains would far outway the negatives. They were right. I have not seen any performance issues with the bigger core and have seen cooling benefits actually.

After much temp testing I found that at cruise I was 8-10 degrees cooler than with my previous core. I also found that max boost temps never exceeded corrected temp values of 132 degrees F at 9.4 psi of boost. This was at outside air temps of 101 degrees (Texas heat).

The other plus I have found with this setup is I always feel like I am driving on a really cool night and the car feels alive and strong even when it has been yes 107 degrees F outside.

AT 9.4 psi cooled I put down 299 whp and 194 TQ. During tuning and dyno runs it was classic 100 degree heat. Unfortunately the IAT sensor I was using within the core at the time was a closed type and was not reading fast enough for us so I had to hookup the stock IAT sensor but have sense corrected the issue by going with a Wells WT382 IAT sensor.

DYNO at 9.4 psi in Texas Heat.

Now that temp testing has been completed and I feel confident that temps are managable at higher boost for short periods of time at WOT I am going to throw on the K24 crank pulley with my 3" blower pulley and this time be able to record temps during the dyno to see how efficient the core is during tuning.
If temps seem still reasonable and the power gained is worth it then I will keep the K24 on and rebuild the blower to better handle the higher speed it must endure.

This is not a cheap upgrade. The cost of this new core is $439 due to the fact that they have to cut down the 6" core to be 4.5". Included in the price is the welding of the endtanks and welding the fittings into the end tank.

Bell Intercoolers Core Design
New Bell Intercooler Core
New Core welded to the blower plate
Newly added expansion tank

I wanted to add a few things to the aftercooler setup listed below.

GOALS:

1. Support the core by welding it to the plate instead of it being supported by the water fittings.
2. Weld the fittings instead of threading them in
3. Reincorporate the bottom support arm for the JRSC blower.
4. Relocate the IAT sensor.
5. Add as much core as possible for efficient cooling.

Thanks goes out to the following ClubRSX members who have been VERY helpful to this project getting me pictures and measurements and opinions as well as ideas.

Sonny
Erik Loza
Brando420
Blacknite