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      08-24-2009, 02:21 PM   #1
klipseracer
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FMIC Comparison - Data Compilation

Please post here with the different options for FMIC's. I will be digging through what is posted here and will try and add what I know. Please feel free to help me out! This thread is not dedicated to any one particular FMIC I want as unbiased of a perspective to be shown as possible.

EDIT: I've stumbled across this snippet from Shiv and I think it is definitely good information to consider when analyzing dyno graphs from FMIC gains. I've edited some of it to be a little more relevant.

Quote:
In my experience, power gains afforded by intercoolers can be a little misleading. Not intentionally but just by the nature of dyno tuning. This goes back to the whole inadequate cooling issues that we see on dynos. Without real 60+mph winds going through the IC, an IC will not operate at peak efficiency. This means that it will not properly transfer heat from the intake charge to the fins, to the ambient air. But not all is lost, even without adequate airflow, the intercooler still has mass. And the heavier it is, the more heat it can steal from the intake charge(klipseracer: Think heat sink on a computer). In some cases (where airflow is low enough), the stock intercooler will operate at just 50% cooling efficiency (as opposed to the usual 80+% it operates in on the road). Whereas a bigger (ie, heavier) IC will still operate at an effective 80% just do to its greater thermal mass. On the dyno, in this case, you will see a huge power differential, esp at high RPM where the heat rejection differential is huge. Of course, without enough airflow, all this cooling ability is temporary. Once either IC absorbs as much heat as it can (through poor airflow and limited cooldown time, it becomes "heat soaked" at which point you are relying completely upon the ability of the core to shed heat from the charge. So what we sometimes end up seeing are 'unfair' dyno tests between a stock intercooler and an upgraded one. Yes, the upgraded one made more power on the dyno where it enjoyed its extra thermal mass. But, on the road, with proper airflow, this advantage doesn't exist. At which point, you are relying on its better efficiency and reduced pressure drop. Which can be substantial in some cases. I'm just not sure that is the case in the BMW when we are only talking 400-450bhp and a pretty large, well-designed stock intercooler to begin with. But again, we will see soon enough. It's just hard to keep up with you guys while giving every level of upgrade a fair shot!
In other words. A HUGE FMIC will show a higher gain on a dyno because it isn't relying on road speed airflow to do its cooling job that the smaller intercooler can not. Think big heat sink vs small heat sink. The larger heat sink will take longer to heat soak, but once they are there, if the design of the larger heat sink is not superior, they will perform exactly the same however the initial dyno may show the larger of the two as much better. Once both heat sinks have absorbed all the heat they can, the only difference between them is their ability to shed heat. A lot of dyno's do not represent the larger FMIC at that 'heat soaked' point where as the stock intercooler will be there much quicker. However, Once out on the road, the smaller intercooler will not have nearly as much of a disadvantage and will not get heat soaked so fast. This is where the design and true efficiency of the intercooler will be realized. And honestly, who does one pull in their can and goes back to park it? I sure don't. This is my daily driver, not a one-off race car.
-----------------------------------------

I'll start with AMS - No particular order. Just the order in which I stumble upon their specs.

Pictures:








Specifications:

Weigth: 17.6 lbs
Dimensions: 20 x 6 x 6
IAT and backpressure testing in progress now.

Stock Core = 4.9375 Tall x 20 Wide x 4.75 Thick
AMS Core = 5.8125 Tall x 20 Wide x 6 Thick


Stock Face Area = 98.75 in^2
AMS Fa Area = 116.25 in^2
AMS has increase of 17.7% in Front Usable face Area over stock

Stock Volume = 469.063 in^3
AMS Volume = 699.5 in ^3
AMS has increase of 49.1% in Volume over Stock

According to Eric@AMS the unit requires minimal cutting 3" inlet and outlet, Comes complete with special couplers to bolt to the factory piping and has incorporated tabs to keep the fan shroud tight. The AMS logo is purely optional. The woman is likely not for sale. Sorry guys.

Pricing:

$799.95 for the first 20
$899.95 Retail

Click here to contact Eric
http://www.e90post.com/forums/privat...=newpm&u=46288

----------------------------------------------

Next up: Helix Stepped Core Intercooler

Pictures:















Specifications:

Fits in stock location- YES
requires NO cutting,removal and/or permanent modification- Yes on 335i, No on 135i
Can it be installed without removing front Bumper- YES
Utilizes factory mounting points- Yes
Design:
More core volume than stock- Yes 56%
More Ambient face than stock- Yes 56%
More charge rows than stock(8)- Yes 13
Bar and Plate construction- Yes
Removes restrictive stock O ring connectors- Yes
Seals to factory radiator fan shroud so air is drawn through when car is not in motion- Yes
Performance:
Helix intercooler at 13.5psi 63 degree ambient temps:
372whp +22whp
turbo outlet temperature 228 degrees F(estimated using a 63 degree ambient and 65% compressor efficiency at 13.5 psi)
AIT temp- 75 degrees F - 54 degree drop over stock
pre and post intercooler temp drop- 153 degrees F
Intercooler efficiency- 93% - 33% improvement in efficiency over stock
Core pressure drop spec is .5psi at 450hp(600cfm) airflow

Helix has opted not to utilize the factory O-ring connectors even though they could have easily implemented them in this design. Their reasoning was simple, the factory connectors are THE flow restriction in the charge side as they shrink down to less than 2 inches in diameter at the inlet and outlet.

Pricing:

Group Buy(Will check if its still open)-
0-9 purchasing participants = $899.00 *save $60*
10-14 purchasing participants = $849.00 *save $110*
15+ purchasing participants = $799.00 *save $160*
Requires $75.00 Deposit

Retail-
$959.00

Click here to contact Alex@Helix
http://www.e90post.com/forums/privat...=newpm&u=27725

------------------------------------

ActiveAutowerke

I'm getting this info from an old post please update me with any current information if it has changed. Thanks!

Pictures:







Note: All testing was done on the same day, same car, same dyno.












These are picture of their prototype, If someone has installed pictures of final product please update me!








Specifications:

1. What are the core's dimensions? 17 wide, 11.7 tall, 3.5 thick

2. What type of core is it? (tube and fin/bar and plate) Bar and Plate
3. What are the hoses made of? silicone
4. What type of hose clamps are included? (cheapo worm gear clamps or t-bolt) cheapo worm gear clamps
5. How much air does the intercooler flow? (what HP is it good for) 550rwhp
6. Is there any hacking/trimming of the metal bumper involved? No
7. Is there any hacking/trimming of the bumper cover involved? No
8. Can we see a side-by-side pic with the stock intercooler?



Pricing:

$1195

Click here to contact Jean:
http://www.e90post.com/forums/privat...=newpm&u=19804


----------------------------------------


Forge

Pictures:









Specifications:

Flywheel figures

Pre Forge intercooler: 381bhp and 376 ft/lb
Post Forge intercooler: 395.7 bhp and 400.2 lb/ft

Dyno Stock car:


Pre Forge Intercooler: 316 BHP and 340 lb/ft
Post Forge Intercooler: 326 BHP and 350 lb/ft

Gain: 10 BHP and 10 lb/ft Torque.


Size details:

Forge Core Volumetric Size : 10679 cm3
OEM Core Volumetric Size: 7293 cm3

Forge Core is 40% larger volume than OEM.

Forge Face Area: 790 cm2
OEM Face Area: 600cm2

Forge face area is 30% larger than OEM.

Weight 7.5 KG/16.5 lbs.

No cutting or trimming required. Fits in stock location without the need to remove the front bumper on both 135i and 335i.

Pricing:

RRP on this intercooler will be 650 inc VAT. Postage to UK will be 25.

Orders outside EU can take 15% off the prices I mention. I will be working out postage to USA and Europe in the next day or so but it will be reasonable.

For the first 10 units we will give 10% off making the intercooler 585 inc VAT.

Click here to contact Imram@Evolve
http://www.e90post.com/forums/privat...=newpm&u=41349

Last edited by klipseracer; 06-27-2011 at 01:23 PM.
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      11-03-2009, 06:40 PM   #2
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Pretty good thread to die at 1 post..

Anybody else got any more information to add?
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      11-03-2009, 07:16 PM   #3
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A few of us running around have the STETT FMIC. You can check out their website, don't know if they post any dyno #'s, etc.

Note the picture of the installed FMIC is not my car (Got PSI's), although it looks the exact same :P

http://www.e90post.com/forums/showth...tt+fmic&page=3

Link to a thread talking all about it.
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      11-03-2009, 08:26 PM   #4
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Theres alot more info on the stett but its rated at 620hp. Yes there is alot trimmimg to the black plastic, oh yeah I think the stett now is around $1100.
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      11-03-2009, 10:15 PM   #5
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Wow, this is great write-up. It will definitely be vital source of info in the future as long as users search.
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      11-03-2009, 11:30 PM   #6
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add in

http://www.evolutionracewerks.com/product.php
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      11-03-2009, 11:41 PM   #7
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wow terrance, the stett is DEF the most aesthetically pleasing!
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      11-03-2009, 11:55 PM   #8
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Quote:
Originally Posted by RevC View Post
wow terrance, the stett is DEF the most aesthetically pleasing!
Active Autowerke looks pretty mean too.

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      11-03-2009, 11:57 PM   #9
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I'm glad someone is finally enjoying my initiative Keep updating with the new cores, prices pictures etc.
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      11-04-2009, 12:02 AM   #10
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Quote:
Originally Posted by klipseracer View Post
I'm glad someone is finally enjoying my initiative Keep updating with the new cores, prices pictures etc.
Edit your first post with whatever new info comes in.
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      11-04-2009, 12:03 AM   #11
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Some more dimensions for Stock IC, AA, and Helix



HELIX
7.81" H x 20.75" W x 5.75" D -total dimensions
Upper face 2.81" x 20.75" x 2.25" = 131ci Core Volume +
Lower Face 5" x 20.75" x 5.75" = 596ci Core Volume = 727ci total core volume
ambient face 7.81" x 20.75" = 162sq/in
-58% more core volume than stock
-59% more ambient face than stock
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      11-04-2009, 12:16 AM   #12
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nice post
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      11-04-2009, 12:41 AM   #13
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and RPi, dont forget about them! ive had their intercooler for almost 2 years now with no issues!

http://shoprpi.com/product_info.php?...products_id=45

click to enlarge the tiny thumbnail photo
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      11-04-2009, 01:28 AM   #14
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Only took 3 months to catch on apparently...
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      11-04-2009, 09:39 AM   #15
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Quote:
Originally Posted by klipseracer View Post
Only took 3 months to catch on apparently...
well i usually dont post unless there's info for another forum member to gain from. whether it be numbers, pictures or videos. in this case, i dont really expect anyone to purchase the RPi i/c. especially not because i said so. i just would like it to be compared to other's out there. its fully interchangable with the stocker, no cutting required. and the endtanks match except they're metal.
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      11-04-2009, 10:27 AM   #16
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Not a big issue, but weights would be a useful datum.
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      11-04-2009, 11:43 AM   #17
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Good info guys...
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      11-04-2009, 12:47 PM   #18
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Quote:
Originally Posted by stressdoc View Post
Not a big issue, but weights would be a useful datum.
Does weight help decipitate heat? AMS IC seems really light.
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      11-04-2009, 01:26 PM   #19
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Quote:
Originally Posted by 09AlpineTTSedan View Post
Does weight help decipitate heat? AMS IC seems really light.
You can't decipitate heat. You can however cool the intake charge through heat exchange. Decipitate means to have the clouds do the opposite of precipitate, which would literally mean to suck rain water back up into the clouds.. And if AMS's intercooler could do that, I'm f*cking sold. But yes, naturally i'm partial to the AMS design because we aren't running 600hp monsters(yet), it 'appears' to be fairly lightweight, not overkill, this aids in efficiency not just on a cooling level but also in the fitment/overall effectiveness department. I personally beleive them to have more well thought out end tanks than others. However, depending on real life data, as well as your future upgrade path, that is still yet to be determined by time and testing.
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      11-04-2009, 02:21 PM   #20
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how about pressure drops for various FMIC... should this be a concern? Few state this in their numbers. Anyone know stock pressure drop?
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      11-04-2009, 04:06 PM   #21
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Quote:
Originally Posted by RevC View Post
wow terrance, the stett is DEF the most aesthetically pleasing!
Yes it definitely looks aggressive, I bought the intercooler cause I don't want to end up trading it out when I one day upgrade the turbos.
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      11-04-2009, 04:29 PM   #22
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I think that AMS has the best looking end tanks that ive seen and a good designed end tank is very important to how it directs the airflow into the core. I think i will be buying the AmS IC.
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