THE LARGEST BMW 2-SERIES FORUM ON THE PLANET
2Addicts
2Addicts
BMW Garage BMW Meets Register Search Today's Posts Mark Forums Read
2Addicts | BMW 2-Series forum Technical Topics N55 (M235i) Engine, Transmission, Exhaust, Tuning THE ULTIMATE Intercooler Thread - What to Look For Before Buying an FMIC

Post Reply
 
Thread Tools Search this Thread
      03-02-2016, 04:36 PM   #1
mike@x-ph.com
Joint Chiefs of Staff
mike@x-ph.com's Avatar
United_States
23788
Rep
190,143
Posts

Drives: 07-335/12-328/18-M4/21-M4CP
Join Date: Sep 2013
Location: Las Vegas

iTrader: (23)

Talking THE ULTIMATE Intercooler Thread - What to Look For Before Buying an FMIC

There has been numerous threads lately about intercoolers. From the usual which one is the best FMIC on the market to Ebay brands claiming to offer a high quality solution for a reasonable price.

I will be discussing the most important factors about intercoolers and why some FMIC will offer better cooling than others

Intercoolers and why replacement is recommended?

Turbochargers compress engine intake air which creates heat. The Intercooler then cools down the charged air. For remapped cars, temperatures up to 200°C after turbocharger can occur. Factory intercoolers are unable to sufficiently handle such high temperatures. This causes high intake temperatures and the oxygen content of the charged air drops significantly. As a direct consequence, the performance decreases, the thermal load on the cylinder head and valves increases. Worst case this can cause severe engine damage.

The colder the intake air, the higher the efficiency of the turbo-charged engine and less risk of engine damage. This can be achieved with an optimized intercooler system installed between the turbocharger and engine.

Construction of an intercooler?

Intercoolers can be categorized by two types of the core construction.

The BAR & PLATE core construction is relatively heavy so there is certain temperature inertia. Meaning under load the core takes longer to heat, but also longer to cool down once the load is removed. This is fine for on the road, but for use on the race track this core construction is not particularly suitable as it arrives at a constant cooling performance at varying loads in the full load range. Also weight reduction is an important consideration for track use.

The fine structure of the TUBE & FIN core makes them relatively light and exchange heat much faster. This type of core construction takes temperatures relatively quickly, but also very quickly transfers this away again. For a constant cooling performance in a dynamic throttle situation this is an indispensable feature. Tube fin intercoolers are suitable for street use as well as at the race track.

The OUTSIDE CORE is responsible for heat exchange with the running wind. The higher the density of the external core (fins), the better the cooling performance of an intercooler. But you also have to look which parts are behind the intercooler. Too much fin density means all parts behind the intercooler will be blocked. The worst case would be, you’ve solved the problem of high intake air temperatures, but the engine coolant temperature climbs. High performance manufacturers note all these factors and develop the most suitable structure of outside core design.

Low Density Core // // // High Density Core
Name:  fin.jpg
Views: 3560
Size:  66.9 KB

Also notice the staggered offset fins for a larger contact area on the intercooler on the right

The INSIDE CORE is responsible for heat exchange with the hot charged air and also need to handle the additional air flow which is running through the intake system. Care needs to be taken when deciding the internal fin density. A high internal fin density gives great cooling performance but with a high pressure drop. The pressure drop of the cooling system should not be adversely affected by an aftermarket intercooler. Less pressure drop reduces the mechanical load on the turbocharger (stability & life time for the turbo). High performance intercooler manufacturers find the best balance between high cooling performance, reduced pressure drop and design their intercooler cores specifically for each vehicle.

The right ENTANK DESIGN is another key consideration when you are looking for the best intercooler for your car. It is easy to see the difference between a good and a bad aftermarket intercooler.

There are different approaches, some manufacturers use sheet metal end tanks and others use cast aluminium end tanks. At flow velocities of around 100 m/s it makes no sense to let the air flow straight in to a wall. This causes unwanted turbulence inside the end tank and higher pressure drop. Furthermore, uniform filling of the intercooler is critical for optimum performance. To aid this, some manufacturers add internal air guides.

Name:  20130712_180435.jpg
Views: 3717
Size:  218.4 KB

Size & Fitment

The size of an intercooler is not always proof of better cooling. There is an old adage which says "Power is nothing without control". This can be applied to bigger intercoolers. If you construct a bigger intercooler without working with internal air guide systems and flow optimized end tanks, the air will not flow through the whole system and choosing a bigger intercooler makes no sense because the intercooler is not being used effectively.

Although the size of the intercooler is changing, the installation should not require mutilation of the vehicle. To avoid nasty surprises you should always look at the installation instructions (if available). Additionally you can seek reviews from neutral and professional sources. I know sometimes it is quite difficult to recognize those sources.

Here is my advice on how to pick the right intercooler for you

Don’t get an intercooler because someone on the forum says it’s cheap, it fits and they feel it is doing a great job. Ask for logs.

Check if the manufacturer invests time and money in development/engineering, to get the latest technology in your intercooler. The needs of the cars and tuning them changes all the time.

Don’t get an intercooler just because people say it is the best. Get an intercooler because professional tuners say it the best. The best intercooler on a fully bolt on car with upgraded turbo might not be the best intercooler for a stock car with stage 1 tune.

Start by thinking ahead in terms of modifications that you will eventually add on your car. If you plan on going fully bolt on in 1-2 years, get an intercooler that suits the fully bolt on application.

Bigger is not always better. If you do not plan on getting stage 2 turbo, don’t get an intercooler built for stage 2 applications. You want an intercooler that provides the best cooling with the minimum pressure drop.

If the right intercooler is over your budget, wait until you have enough funds or try saving on other mods so you can get the right intercooler.

Ebay Notes

Some justify getting an ebay intercooler for the following reasons:
  • Daily driver, No track use ever
  • conservative tune
  • Looking for a cheap solution that works, even if it is not the best one available

As mentioned above, getting a bigger intercooler does not always mean you are getting better performance. You might get better IAT than stock, but your pressure drop will be higher and so the couple hundred dollars you spent on a cheap solution did not help.

If you are not going to pick a brand that takes into consideration everything mentioned above, you are better off keeping your stock intercooler.

As i said earlier, dont get the biggest most expensive FMIC if your car is a daily driver with stage 1 tune. Talk to vendors / tuners, tell them your HP goals and mods + your budget. They will recommend an FMIC that suits your needs.
__________________
Check out our current sale by clicking on this link!
https://x-ph.com/sale/

Phone number 702-494-9435
Appreciate 5
Lozza4737.50
NDAzone13.50
      03-02-2016, 11:57 PM   #2
PeterPure
Major
PeterPure's Avatar
Belgium
677
Rep
1,349
Posts

Drives: BMW F80 M3
Join Date: Jun 2008
Location: Belgium

iTrader: (0)

Garage List
2017 BMW F80 M3  [0.00]
Indeed i have said in my reviews before as well there is not 1 best intercooler. It depends on how you use the car and its mods.

Good writeup!
Appreciate 0
      03-03-2016, 01:07 PM   #3
Liquidpaper
Captain
Liquidpaper's Avatar
United_States
450
Rep
845
Posts

Drives: '15 M235i
Join Date: Jun 2014
Location: SoCal

iTrader: (0)

Garage List
2015 BMW M235i  [0.00]
Great advice. Always ask people who do this for a living -- they usually know more than you.
__________________
Appreciate 0
      03-03-2016, 03:16 PM   #4
mike@x-ph.com
Joint Chiefs of Staff
mike@x-ph.com's Avatar
United_States
23788
Rep
190,143
Posts

Drives: 07-335/12-328/18-M4/21-M4CP
Join Date: Sep 2013
Location: Las Vegas

iTrader: (23)

Quote:
Originally Posted by Darkiedm4 View Post
Indeed i have said in my reviews before as well there is not 1 best intercooler. It depends on how you use the car and its mods.

Good writeup!
Thank you

Enjoyed your reviews as well
__________________
Check out our current sale by clicking on this link!
https://x-ph.com/sale/

Phone number 702-494-9435
Appreciate 1
      03-03-2016, 03:18 PM   #5
mike@x-ph.com
Joint Chiefs of Staff
mike@x-ph.com's Avatar
United_States
23788
Rep
190,143
Posts

Drives: 07-335/12-328/18-M4/21-M4CP
Join Date: Sep 2013
Location: Las Vegas

iTrader: (23)

Quote:
Originally Posted by Liquidpaper View Post
Great advice. Always ask people who do this for a living -- they usually know more than you.
Would like to add one thing to your post.

Make sure the person you ask offers a variety of brands so they can give you an honest opinion rather than just sell you what they have
__________________
Check out our current sale by clicking on this link!
https://x-ph.com/sale/

Phone number 702-494-9435
Appreciate 1
BM235iW97.00
      03-04-2016, 09:33 AM   #6
AlexGT
Captain
AlexGT's Avatar
Guatemala
417
Rep
809
Posts

Drives: G05 X5 MSport
Join Date: Apr 2012
Location: Guatemala

iTrader: (0)

Great writeup mike, thanks for sharing it. In my personal case, I "think" I did a good investment with the Wagner Performance IC, I was told not to get the "Competition" model if I wasn't going to be doing track days often.
Appreciate 0
      03-04-2016, 02:07 PM   #7
mike@x-ph.com
Joint Chiefs of Staff
mike@x-ph.com's Avatar
United_States
23788
Rep
190,143
Posts

Drives: 07-335/12-328/18-M4/21-M4CP
Join Date: Sep 2013
Location: Las Vegas

iTrader: (23)

Quote:
Originally Posted by AlexGT View Post
Great writeup mike, thanks for sharing it. In my personal case, I "think" I did a good investment with the Wagner Performance IC, I was told not to get the "Competition" model if I wasn't going to be doing track days often.
You are welcome!!

Competition is more for track days. If you do not track your car often, performance is the way to go
__________________
Check out our current sale by clicking on this link!
https://x-ph.com/sale/

Phone number 702-494-9435
Appreciate 1
      07-05-2018, 10:34 AM   #8
mike@x-ph.com
Joint Chiefs of Staff
mike@x-ph.com's Avatar
United_States
23788
Rep
190,143
Posts

Drives: 07-335/12-328/18-M4/21-M4CP
Join Date: Sep 2013
Location: Las Vegas

iTrader: (23)

Active Autowerke FMIC vs stock
__________________
Check out our current sale by clicking on this link!
https://x-ph.com/sale/

Phone number 702-494-9435
Appreciate 0
      07-05-2018, 03:17 PM   #9
aschmitty6
Enlisted Member
4
Rep
44
Posts

Drives: M235i
Join Date: Mar 2018
Location: Germany

iTrader: (0)

I plan on running FBO w/ BM3, stock turbo, would the VRSF HD FMIC provide adequate cooling?
Appreciate 0
      07-05-2018, 03:41 PM   #10
mike@x-ph.com
Joint Chiefs of Staff
mike@x-ph.com's Avatar
United_States
23788
Rep
190,143
Posts

Drives: 07-335/12-328/18-M4/21-M4CP
Join Date: Sep 2013
Location: Las Vegas

iTrader: (23)

Quote:
Originally Posted by aschmitty6 View Post
I plan on running FBO w/ BM3, stock turbo, would the VRSF HD FMIC provide adequate cooling?
It sure does
__________________
Check out our current sale by clicking on this link!
https://x-ph.com/sale/

Phone number 702-494-9435
Appreciate 0
      01-22-2020, 11:09 AM   #11
mike@x-ph.com
Joint Chiefs of Staff
mike@x-ph.com's Avatar
United_States
23788
Rep
190,143
Posts

Drives: 07-335/12-328/18-M4/21-M4CP
Join Date: Sep 2013
Location: Las Vegas

iTrader: (23)

__________________
Check out our current sale by clicking on this link!
https://x-ph.com/sale/

Phone number 702-494-9435
Appreciate 0
      01-28-2020, 11:51 AM   #12
mike@x-ph.com
Joint Chiefs of Staff
mike@x-ph.com's Avatar
United_States
23788
Rep
190,143
Posts

Drives: 07-335/12-328/18-M4/21-M4CP
Join Date: Sep 2013
Location: Las Vegas

iTrader: (23)

VRSF Intercooler vs stock
__________________
Check out our current sale by clicking on this link!
https://x-ph.com/sale/

Phone number 702-494-9435
Appreciate 0
      01-28-2020, 12:06 PM   #13
whoismorggan
Bimmer Nut + Software Dev
whoismorggan's Avatar
551
Rep
801
Posts

Drives: 2018 Audi S3 Premium +
Join Date: Aug 2017
Location: Raleigh, NC

iTrader: (1)

Garage List
Quote:
Originally Posted by mike@x-ph.com View Post
VRSF Intercooler vs stock
Is that the 5" Competition IC?
__________________
Current: 2018 Audi S3 Premium +
Past: '08 Infiniti G37S, '87 Porsche 944 Turbo, '13 328i, '15 M235i, '15 F80 M3, '16 M235i, '15 335i, '17 X5 xDrive35i
@whoismorggan
Appreciate 0
      01-28-2020, 03:09 PM   #14
mike@x-ph.com
Joint Chiefs of Staff
mike@x-ph.com's Avatar
United_States
23788
Rep
190,143
Posts

Drives: 07-335/12-328/18-M4/21-M4CP
Join Date: Sep 2013
Location: Las Vegas

iTrader: (23)

Quote:
Originally Posted by f20two View Post
Is that the 5" Competition IC?
I believe so
__________________
Check out our current sale by clicking on this link!
https://x-ph.com/sale/

Phone number 702-494-9435
Appreciate 1
      01-29-2020, 04:55 PM   #15
Dynamic_m235
Lieutenant
74
Rep
410
Posts

Drives: 2016 m235i xDrive
Join Date: Feb 2017
Location: North Jersey

iTrader: (1)

Csf all day
Appreciate 1
      03-03-2020, 12:32 PM   #16
mike@x-ph.com
Joint Chiefs of Staff
mike@x-ph.com's Avatar
United_States
23788
Rep
190,143
Posts

Drives: 07-335/12-328/18-M4/21-M4CP
Join Date: Sep 2013
Location: Las Vegas

iTrader: (23)

VRSF F chassis Intercooler

__________________
Check out our current sale by clicking on this link!
https://x-ph.com/sale/

Phone number 702-494-9435
Appreciate 0
      03-18-2020, 04:43 AM   #17
lmach
New Member
Australia
59
Rep
26
Posts

Drives: 2018 M2 LCI
Join Date: Mar 2020
Location: QLD, Australia

iTrader: (0)

Can anyone please tell me what the fitment of the VRSF 6.5" Competition HD Intercooler is like in a 228i?

Is it worth getting the 6.5" over the 5" for Bootmod3 Stage 2?
Appreciate 0
      03-18-2020, 10:34 AM   #18
mike@x-ph.com
Joint Chiefs of Staff
mike@x-ph.com's Avatar
United_States
23788
Rep
190,143
Posts

Drives: 07-335/12-328/18-M4/21-M4CP
Join Date: Sep 2013
Location: Las Vegas

iTrader: (23)

Quote:
Originally Posted by lmach View Post
Can anyone please tell me what the fitment of the VRSF 6.5" Competition HD Intercooler is like in a 228i?

Is it worth getting the 6.5" over the 5" for Bootmod3 Stage 2?
Hi,
Yes, it is. You're going to need the additional cooling that the 6.5" offer with stage 2 power
__________________
Check out our current sale by clicking on this link!
https://x-ph.com/sale/

Phone number 702-494-9435
Appreciate 1
lmach58.50
      03-18-2020, 04:04 PM   #19
AmuroRay
Brigadier General
AmuroRay's Avatar
2165
Rep
4,073
Posts

Drives: M235i
Join Date: Aug 2019
Location: Florida

iTrader: (0)

Quote:
Originally Posted by mike@x-ph.com View Post
Hi,
Yes, it is. You're going to need the additional cooling that the 6.5" offer with stage 2 power
Can you tell me all the 6”. Or larger cores you have? I keep seeing the VRSF race and competition - but are they the same? Any fit issues?
Appreciate 0
      03-18-2020, 05:32 PM   #20
mike@x-ph.com
Joint Chiefs of Staff
mike@x-ph.com's Avatar
United_States
23788
Rep
190,143
Posts

Drives: 07-335/12-328/18-M4/21-M4CP
Join Date: Sep 2013
Location: Las Vegas

iTrader: (23)

Quote:
Originally Posted by AmuroRay View Post
Can you tell me all the 6”. Or larger cores you have? I keep seeing the VRSF race and competition - but are they the same? Any fit issues?
Wagner EVO II Competition
Wagner EVO III Competition
CSF
Evolution Racewerks
VRSF 6.5" Competition
VRSF 6.5" Race
__________________
Check out our current sale by clicking on this link!
https://x-ph.com/sale/

Phone number 702-494-9435
Appreciate 0
      04-17-2020, 11:26 AM   #21
mike@x-ph.com
Joint Chiefs of Staff
mike@x-ph.com's Avatar
United_States
23788
Rep
190,143
Posts

Drives: 07-335/12-328/18-M4/21-M4CP
Join Date: Sep 2013
Location: Las Vegas

iTrader: (23)

VRSF 5" Intercooler HD

__________________
Check out our current sale by clicking on this link!
https://x-ph.com/sale/

Phone number 702-494-9435
Appreciate 0
      04-17-2020, 11:45 AM   #22
AmuroRay
Brigadier General
AmuroRay's Avatar
2165
Rep
4,073
Posts

Drives: M235i
Join Date: Aug 2019
Location: Florida

iTrader: (0)

Quote:
Originally Posted by mike@x-ph.com View Post
Wagner EVO II Competition
Wagner EVO III Competition
CSF
Evolution Racewerks
VRSF 6.5" Competition
VRSF 6.5" Race
Thank you!
Appreciate 0
Post Reply

Bookmarks

Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off



All times are GMT -5. The time now is 04:09 PM.




2addicts
Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2024, vBulletin Solutions Inc.
1Addicts.com, BIMMERPOST.com, E90Post.com, F30Post.com, M3Post.com, ZPost.com, 5Post.com, 6Post.com, 7Post.com, XBimmers.com logo and trademark are properties of BIMMERPOST