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You obviously can't just have an open-end on the intercooler outlet and expect to make really high pressures through the core. The idea is simply to use a ball-valve on the end of a ~6" tube with 2.0" o.d. connected to the outlet of the intercooler to allow control of the flow/pressure. We will need a little bit of lead pipe after the intercooler to put the temperature and pressure sensors in place The testing procedure with a setup like this will be to test the intercooler in several different ways. The tests will go as follows: The intercooler efficiency will be tested over about 25 different conditions. The variables that will be controlled are airflow and pressure. A crude example: Test1:
5psi inlet pressure, 100CFM: Measure T1, T2, P1, P2.
5psi inlet pressure, 200CFM: Measure T1, T2, P1, P2.
5psi inlet pressure, 300CFM: Measure T1, T2, P1, P2.
5psi inlet pressure, 400CFM: Measure T1, T2, P1, P2.
5psi inlet pressure, 500CFM: Measure T1, T2, P1, P2. Test2:
10psi inlet pressure, 100CFM: Measure T1, T2, P1, P2.
10psi inlet pressure, 200CFM: Measure T1, T2, P1, P2.
10psi inlet pressure, 300CFM: Measure T1, T2, P1, P2.
10psi inlet pressure, 400CFM: Measure T1, T2, P1, P2.
10psi inlet pressure, 500CFM: Measure T1, T2, P1, P2. Test3:
15psi inlet pressure, 100CFM: Measure T1, T2, P1, P2.
15psi inlet pressure, 200CFM: Measure T1, T2, P1, P2.
15psi inlet pressure, 300CFM: Measure T1, T2, P1, P2.
15psi inlet pressure, 400CFM: Measure T1, T2, P1, P2.
15psi inlet pressure, 500CFM: Measure T1, T2, P1, P2. ...and so on and so forth, up to ~30psi inlet pressures. Several different graphs can be produced from this information. One can relate pressure drop based on CFM and airflow. Another can relate efficiency based on CFM and airflow. An additional fan/shroud setup will need to be built to provide a metered amount of ambient airflow for cooling of the core. A labjack connected to my PC and a program to handle this sort of testing can be created to provide all of the data acquisition.
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