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how make a air to air intercooler

7.7K views 49 replies 9 participants last post by  blownstang  
#1 · (Edited)
need help on how to make air to air intercooler

hi everyone, iam new here. i bought a 02 gt two months ago. its my first one. i installed a vortech supercharger kit from summit and works awesome alot of power and now i installed a air to air intercooler kit bought it from ebay. came with a bov. got most of it installed just dont know if i need a bov or use the vortech one and where does it go. i been looking around the internet but just cant find directions. any help? thanks alot.i also installed bbk hi-flow cats,magnaflow cat back. 75mm tb bbk, and uper intake. any idea on hosepower? thanks
 
#4 ·
i had to send my computer to vortech so my tune is from vortech. i have the stock plastic bov that came with the kit. i dont know the different between the blow thru maf or draw thru sorry.
 
#3 ·
You can use the same blow off/bypass valve, depending on how much boost, you may need 2. Or just a stronger one. Like the Procharger Pro-flo, or whatever

You want to put it right after the head unit. Like a couple inches to a foot down. So inbetween the supercharger and inlet of the intercooler.
 
#7 ·
i tried that with the bov that came with the intercooler kit and made no boost. if i use the stock one do i just leave it where it is? i want to buy the vorteck mini bov one day. i made around 8 pounds of boost so far i think the kit says 7-9 pounds.
 
#6 ·
Yea you need a custom dyno tune. Its much more worth it, and a lot safer.

You can use the stock bosch bypass valve, but you may need 2. Also how much boost are you making? With an intercooler, its gonna go way down. Those ebay intercoolers drain boost because there pretty big. If your making 10psi youll probally go to 5, 6 or 7psi
 
#13 ·
i made around 8psi of boost. my intercooler is pretty big. vortech custom tune my computer but i do wanna take it to the dyno. do you think i need a intercooler with 8-9psi of boost? thanks
 
#8 ·
You made no boost? You must have an intercooler leak then. If you use the stock bypass/blow off valve, it needs to be a few inches down after the supercharger.
 
#10 ·
tomorrow i will check everything and try the stock bypass on the intercooler. thanks for all the info. i love to learn more. thanks again everybody. if their is anything else i schould be doing or have please let me know. like i said this is my first mustang. i had alot of chevys and now i am a ford guy.
 
#11 ·
No hes saying its not the best way, meaning the best way is a custom dyno tune. Getting your computer re-flashed isnt as acurate as a dyno tune. Dyno tune you can view live data with the car running to check IAT's, air fuel ratio, throw in timing or pull timing etc.... I say get a custom dyno tune for sure, money well spent.
 
#16 ·
i see why you guys say to get it dyno. vortech supercharger is for a stock car and my is not i have other work done to it. i can be losing power i am going to look for a dyno place around me in the morning. thanks alot
 
#17 ·
With the intercooler youll lose boost for sure, youll want a smaller pulley most likley
 
#18 ·
guys i am still not done with the intercooler but was wondering if i should get a anderson power pipe instead of the intercooler? or can i use both. i was also told to get a new maf but then i would need it tuned. cant i just get the maf tuned? my local tunner said it would cost around $700 to get my car tuned is that right? they said i would need a hand held programer.
 
#19 ·
If you are using the stock maf you are running a draw thru setup. Yes, you can use a powerpipe and intercooler. The stock maf will peg. You can either buy a Diablosport mafia extender to increase the voltage of the stock maf, or get a 90mm lightning maf. The bypass valve goes in a different place if you are draw thru than if you were blow thru. I would get The Vortech maxflow mini race bypass if I were you. You need to mount it on a 45 degree angle pointing towards the supercharger on the disharge pipe that goes to the throttle body. You will also need to dump it back in the powerpipe using a hose. My V1 is making 8psi with a 3.6 pulley and powerpipe. If you add an ebay intercooler you will see boost drop by around 2 psi. You will want to get a 3.33 pulley or smaller. You definitely need to get the car dyno tuned and not just have Vortech reprogram your computer. $700 is a good price for a dyno tune and hand held programmer. Which tuner are you talking to?
 
#21 ·
your bypass/blowoff valve (they Are the same thing!!!! only bypass simply redirects the pressure back into the intake where the blow off releases the pressure atmosphere)

The correct setup for you, for a draw through application is:

Intake to supercharger > Blower > Blow Off Valve BEFORE intercooler > Intercooler > MAF > IAC nipple > Throttle body


that is how yoru system should be set up (correctly)
 
#23 ·
You just described a blow thru setup, not a draw thru.

Blow thru is: powerpipe, supercharger, bypass/blow off valve, intercooler, maf, throttle body

Draw thru is: maf, powerpipe, supercharger, intercooler, bypass/blow off valve, t/b
 
#22 ·
nice enging bay. i love your set up thats what i want. the tunner is called realspeed on long island. i have the pipe that the vortech mini bypass will go on. so i am going to buy a vortech mini bypass and a 3.33 pully and a maf 90? what would be the best route with a maf? should i buy a voltage extended or a new maf? if i get the lighting mass air 90 does it come tuned or i have to get my whole car tuned? thanks alot for the info.
 
#24 ·
I'm still non-intercooled. Neither of those are my engine bay. It's better to get a bigger maf opening to allow for more air. You can get the 90mm lightning maf, which should be good to around 400rwhp then you could always add the mafia extender to it if it does peg, or you can get a 90mm SCT 2400 maf which is a bit more money, over $200 new, but I believe it is good to like 600hp with a centri blower. I bought a used lighting maf for $60. I've seen used SCT 2400 mafs for around $150. They usually work well with 39lb cobra injectors or 42lb injectors, but you tuner should be able to calibrate the maf to your 36lb injectors (i think that's what comes with the Vortechs) in the tune. You need to get the car dyno tuned.
 
#25 ·
i have 38lb. injectors thats what came with my kit. so if i get a new maf90mm is it tuned already? i think right now i wont use the intercooler to many things to get right now and just go with the anderson power pipe for now.
 
#26 ·
No. Your tuner will have to make an adjustemnt. Think it's called the maf transfer function. You can get powerpipes for cheaper than the Anderson one. Kurgan Motorsports sells all aluminum powerpipes for around $250. MPH (Mr. Norm's Garage) sell theirs for $199, but I think it is made out of pvc.
 
#30 ·
make your own power pipe.. all it is (over the stock vortech intake) is a actual cylinder pipe, and not smashed flat like the stock vortech intake... there is no engineering in it.
 
#31 ·
OH, btw. I have the stock MAF w/ a mafia extender and I was running 450 rwhp w/out a problem. Just another thing to put out there.
 
#32 ·
hi everyone, iam new here. i bought a 02 gt two months ago. its my first one. i installed a vortech supercharger kit from summit and works awesome alot of power and now i installed a air to air intercooler kit bought it from ebay. came with a bov. got most of it installed just dont know if i need a bov or use the vortech one and where does it go. i been looking around the internet but just cant find directions. any help? thanks alot.i also installed bbk hi-flow cats,magnaflow cat back. 75mm tb bbk, and uper intake. any idea on hosepower? thanks
I've read the thread and there is a lot of speculation about your configuration. You need to tell us. Where is your MAF located? Where is your by-pass valve located? A non-intercooled system puts them in a different place than an intercooled system.
 
#33 · (Edited)
thanks for all the great info evertone. my maf is in the fender where vortech wants it and the same for the by-pass valve on the same tube the inlet duct. i have the v-1 vortech supercharger with 3.60 pully on it. i installed a ebay intercooler but it never made boost so i took two pipes off and whent back to the vortech pipes. i would like to get it working again but i found out i need a smaller pulley and i want to get the mini vortech blow off valve and maybe a anderson power pipe but i dont know if it would work with my set up for the intercooler. i now realized from you guys telling me that i should get a new maf too. alot of things to get and then a tune. so what i might do for the mean time is just order a power pipe or see if i can make one. thanks for all the info keep it coming guys i love all this great info. i just got home from driving my car looking for someone to race. i still havent raced anyone yet with my car. i bought my mustang about 2 months for $6000 had cragers rims magnaflow cat back bbk 75mmtb and upper intake and a $400 hypertech programer. then i bought the supercharger kit for $3000 installed it myself and then bbk hi-flow cats and halo headlight and new taillights and the 3 post gauge piller and of course a 2-way alarm and a amp and kicker. and the brace for the engine bay. and a ebay intercooler and new plugs i bought all of this stuff with in two weeks of buying the car and i cant stop buying stuff for it. lol. i had a lot of firebirds and camaros but this is the best car i ever owned.
 
#34 · (Edited)
If u end up putting the intercooler back on you have to move the blowoff valve to the pipe before the intercoller. If you don't you will never be able to tune the car down low. Trust me I went through this situation already. Without going into crazy details, the intercooler acts like the throttle body when the butterfly valve closes (creating a wall for the air that the blower is still pushing (because it is still spinning, even with no throttle)). The problem with this is that the air still has to go somewhere, and because ur blowoff valve is currently after the intercooler, the path of least resistance (for the air the blower is still pushing) is back where it came, through the blower. The sound that this makes can easily be mistaken for a blowoff valve noise, but its air fluttering back out through the air filter.

Now you blowoff is currently hooked up to discharge the air from the pipe on the throttle body back into the vortech intake. It is not the other way around.

If you are keeping the car around 400ish keep the stock maf and get a mafia extender. U do not need to buy a new blowoff valve


The intercooler should only drop about 2 lbs of boost of what u would be making without. If you wernt making boost with the intercooler then you are only making like 2 lbs now or u did something wrong ( the vortech install guide doesn't explain much for a intercooled setup I don't think)

What pulley did you say you have on there now? With a 3.6 pulley and a intercooler ( I have the cx racing one) u should be making about 7 lbs of boost. Sorry if this seems rushed I'm typing on my blackberry at work
 
#35 ·
thanks for the great info. i have a 3.60 pulley on it now. i have seen around 8-9psi of boost without the intercooler. the kit says i should make around 7-9 so i think i am right on. can i use the bypass valve that came with the kit with my intercooler? if i can where do i hook it up same place? and where would the end of it go? i will look on buying a mafi extender. i think if my car is making around 400 thats fine for me. so when i hook up my intercooler again i will need the mafi extender and a smaller pulley and use the stock bypass? thanks
 
#36 ·
+1
You need to move the blow-off valve to the pipe that fits between the supercharger and the intercooler. This does two things. It prevents supercharger surge and it increases the efficiency of your intercooler since it's only cooling air that is actually used. I'm running a stock MAF with a Diablosport MAFia. It works great.
 
#37 ·
so if i want to use the bov that came with the vortech supercharge for my intercooler i would move it after the intake? and if i do that where do i put the hose part? on the pipe that it came off of? can anyone tell me what i do need and where it goes so i can finish my intercooler set up? this is what i think i need. i have the intercooler. so what i need is a new bov or by-pass or use my stock one. then a new pully a 3.33. then a new maf or the mafi extender? i then of course a tune but i think i can get away with it for now.
 
#38 ·
so if i want to use the bov that came with the vortech supercharge for my intercooler i would move it after the intake? and if i do that where do i put the hose part?
If you are running a blow-though systems, which is highly recommended, then the by-pass/blow-off valve needs to be located between the supercharger and the intercooler. A by-pass setup has a hose that goes back to the intake that goes into the supercharger. A blow-through setup doesn't worry about it and just vents to atmosphere.

My system started out with a by-pass valve. It is now a blow-off valve because I disconnected the hose that went back to the intake. It just vents into the engine bay.
 
#39 ·
you will need to do some research on your own, because its not going to be as easy as just "doing it".

You will need to have a nipple welded for where you are going to move the new Blowoff/bypass valve (you can reuse the one you have currently)

Its not as easy as us just telling you waht to do. Are you going to keep your system as a draw through? I highly recomend that you switch to a blow through system. Like Eagle, I also started off as a "draw through" system, but ended up with a blow through once everything was said and done.

What do you plan on doing? keeping a draw through, or doing what is recommended, and switching to a blow-through?