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4) intercooler has the inlet on the top half of the core, but the outlet on the bottom half of the core, and i'm not sure this is the best for flow...

There is a good reason to be doing this. It helps ensure that all the runners inside the intercooler get equal airflow. So by makign sure air passes through the intercooler evenly you are maximising its effeciency. A good example is an EVO intercooler. Look at how many big HP EVO cars run the std cooler. Hell you see EVOs running sub 58s laps at Tsukuba so that general desing has to have merits (Ditto cooler on LeMans cars etc)

even easier .. T it into your BOV pressure feed .. done

Your BOV normally gets its signal from the inlet manifold. Generally it is recommended that you get your boost signal from the intercooler pipes or pre throttle body. Why thats the case i dont know, but most instruction manuals state thats how to do it. And also i suspect a pressure signal off a BOV would pulsate or be unstable pending what the BOV and the throttle are doing?!?!?

SO just get a threaded barb and carefully drill a hole and tap a hole. Hell if the pipe is alloy and you use a stainless barb etc you wont even need to tap it, just use a neat bit of thread tape. (Saves welding one)

Your BOV normally gets its signal from the inlet manifold. Generally it is recommended that you get your boost signal from the intercooler pipes or pre throttle body. Why thats the case i dont know, but most instruction manuals state thats how to do it. And also i suspect a pressure signal off a BOV would pulsate or be unstable pending what the BOV and the throttle are doing?!?!?

SO just get a threaded barb and carefully drill a hole and tap a hole. Hell if the pipe is alloy and you use a stainless barb etc you wont even need to tap it, just use a neat bit of thread tape. (Saves welding one)

this is true roy, but a pressure feed is a pressure feed..

running a boost crontrol from the thing where boost is measured makes more sense to me.

just say in a higher boost situation where the intercooler is not working efficiantly then you will see a drop in pressure at the inlet plenum and possible rise turbo side of the cooler.. which would cause the wastegate to open further and reduce boost pressure at the plenum .. hence why alot of cars drop boost down the rev range.

thats my reasoning for using a plenum based feed for the boost control..

Edited by Craved

Yeh i suppose it depends on your form of boost control? If its electronic you can still run the MAP sensor straight off your inlet manifold. But the line you use to cheat the wastegate can be the outlet of the turbo or anywhere before the throttle body

If its a mechanical means of boost control then fair enough. But again running a t-piece from the BOV line may mean you end up with 450mm or so of tube, and generally the shorter the hose the more accurate the boost control (I assume thats why they run it off the compressor cover as std on RB20s)

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