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BMW 3-Series (E90 E92) Forum > E90 / E92 / E93 3-series Powertrain and Drivetrain Discussions > N54 Turbo Engine / Drivetrain / Exhaust Modifications - 335i > AMS intercooler design for the 335/135



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      02-03-2009, 05:13 PM   #1
Eric@AMS
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AMS intercooler design for the 335/135

As many of you know we have been working on a line of products for the N54. With the exhaust system underway and turbo kit engineering starting any day now I thought I would drop some information on our front mount intercooler.

We have been producing quality intercooler cores for cars for over 7 years. Designing a core for a car isn't the easiest thing to do. Some might think the best way to go about this is shove the largest core possible in the space provided. That is not the case. You have to determine core construction like Bar and plate or tube and fin and also the volume of air passing through the core. Chose the wrong setup or dimensions and you can cause pressure drop. Too big and you can create added lag. Too small and it wont be as efficient or heat soak quickly. Choosing the right core is all about consistency. Ideally you want there to be a little variation between runs as possible and provide consistently cool intake air temps at the engine.

Not only did we choose a great core but we also did our homework and created some VERY free flowing endtanks. We are having them cast to aid in performance and to make sure this is a piece that will last.

The factory c-clip design is unique but we fear with the increased air that we are going to toss at the car with a GT35R that they might not be up to the challenge. This is why we will be including special silicone couplers and aluminum piping along with the intercooler to replace the factory C-clip setup.

Lastly price. With Everything we talked about above we are going to be able to offer this to the public for $1099.95. We might even have an introductory sale once we have units to release.

This core is being built to be used with those running the stock turbo or those looking to get into our turbo kit down the road.

expected release date is about 12-14 weeks.

and here is a CAD design of the core currently:








Eric

Last edited by Eric@AMS; 04-24-2009 at 04:44 PM.
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      02-03-2009, 05:14 PM   #2
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Looks good guys!
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      02-03-2009, 05:17 PM   #3
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patiently waiting
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      02-03-2009, 05:35 PM   #4
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I dig it.

I wonder, why does no one round / wedge the fronts of the bars to try to ram-air more flow into the fins?

-scheherazade
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      02-03-2009, 05:36 PM   #5
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Lookin' good Eric!
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      02-03-2009, 05:43 PM   #6
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2007 E92 335i  [0.00]
looks nice, in 3-4 months, im curious to see the gains!
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      02-03-2009, 05:44 PM   #7
Eric@AMS
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Gains we will have much sooner as we are going to make a prototype here with a quick cast version of the tanks to ensure that we have the correct design.

Eric
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      02-03-2009, 05:47 PM   #8
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Quote:
Originally Posted by scheherazade View Post
I dig it.

I wonder, why does no one round / wedge the fronts of the bars to try to ram-air more flow into the fins?

-scheherazade
you would need to see a cross section to have it make sense but the bar and plate core is just that...a Bar and plate square section with channels to route air. I will try and find you a nice cross section here soon to show what I mean.

Some JDM companies do exactly what you are speaking of but they are a tube and fin core that can't carry as much air.

To give you an idea most factory cores (N54 included) are tube and fine based. its a much cheaper core to manufacture.

Eric
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      02-03-2009, 05:47 PM   #9
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thats enough time for me to start saving up
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      02-03-2009, 05:49 PM   #10
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Quote:
Originally Posted by scheherazade View Post
I dig it.

I wonder, why does no one round / wedge the fronts of the bars to try to ram-air more flow into the fins?

-scheherazade
I take there is enough depth in the E9x bumper to provide that ram air effect, you'll have effectively a 'high' pressure zone in front of the intercooler. What wonders me is why no-one offers a bolt on fine protective mesh say 1" in front of the IC, so that after a year it still looks and performs like new, instead of having been bombarded by stones and do I know what..
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      02-03-2009, 05:50 PM   #11
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Awesome If you need a 135i test car let me know Hopefully this will be just a bolt on
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      02-03-2009, 06:08 PM   #12
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That looks great dude!
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      02-03-2009, 06:10 PM   #13
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+1 for group buy intro pricing !
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      02-03-2009, 07:16 PM   #14
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I am sure we can work out a group buy price for you guys. I do not want to do so however until we have some hard data an we are within a couple weeks of releasing it. We are not in the business of taking money from customers without a reasonable shipping date. That's just bad business and bad customer service.

I am sure we can work something out for you guys. Maybe close to the $999.00 area for a one week group buy. We will see what final costs come to

Thanks again for the support everyone!

Eric
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      02-03-2009, 07:21 PM   #15
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looking forward to seeing it......
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      02-03-2009, 07:58 PM   #16
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Where do I pay?!

Looks great Eric. Looks like I'm gonna hold off on an intercooler also. lol.
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      02-03-2009, 08:37 PM   #17
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very nice eric.. ive seen alot of the work you guys have done and this will be nice
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      02-03-2009, 09:07 PM   #18
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Looks good!

Please have all the info listed at the time of the group buy including ease of install, dynos, etc.
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      02-03-2009, 09:15 PM   #19
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i'll be up next friday to pick one up hahahaha

wish they were avaliable NOW
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      02-03-2009, 09:26 PM   #20
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Looking good. Excited to see the finished product.

Mike
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      02-03-2009, 09:58 PM   #21
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Hey Eric, Nice to see you in here.. let me ask you.. Why is it these 335i cores cannot be made taller to give more surface area?? Active is the only company i have found that is making the cores taller.. There must be enough room if the active core fits.. I havent taken my bumper off yet since i only got the car 5 days ago but i am curious if you have any insight.. Thanks!!

Mike
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      02-03-2009, 10:09 PM   #22
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Looks Great Eric, put me down for the Group Buy!
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