[roh92cp]

Hi guys, I am new member here in the tunning world and really enjoy the great support here. I just wanted to share with all of you my recent article on 5.0 Mustangs & Super Fords magazine page 152 called Frankenstien Foster. I just did an Air to Air intercooler project on my 92 Kenne Bell supercharged 92 coupe. Lots of cutting and hacking and welding to get the job done but its worth it and it really works.

[cougarnut281]

Did you get any of your ideas for this project from the old supercoupes? The setup looks somewhat similar though in all fairness I don't think there are many ways to add a front mount to a P.D. blower.

[roh92cp]

Did you get any of your ideas for this project from the old supercoupes? The setup looks somewhat similar though in all fairness I don't think there are many ways to add a front mount to a P.D. blower.

I've never seen the supercoupe setup, but I got my inspiration from another Corral member who had done this on his 95 Cobra 5 years ago. I followed his idea but improved upon it in it many ways. Here is how I did it.

Ok guys, I said I would do a DIY and build list thread for my Fox body KB A2A project. I had most of this on another thread but this is step by step. I hope this thread helps other fox owners to find and search for this idea.


]Parts list
3" intercooler pipe all 18" length

2 U bend
1 S bend
4 90 deg L bend
1 staight pipe

6 striaght silicone 3 ply couplers
2 45 deg elbows
16 stainless steel T bolt clamps

I baught this from from CX racing and I called them and had them sub i straight pipe for S bend pipe and 2 silicone couplers for 45 Deg elbows. They were very nice and didn't charge extra.
http://cgi.ebay.com/ebaymotors/ws/eBayI ... &viewitem=

Intercooler also from CX racing 31x12x3" with 3" inlet outlet
http://cgi.ebay.com/ebaymotors/CXRacing ... ccessories

For bypass relocation

I used a piece of 1.5" pluming pipe from harware store 16" long with a 90* bend at the end. cut the end to make it fit.

1.5" 45 deg silicone elbow

1.5" ID greddy flange that was welded to 3" pipe

1.5" 45 deg bend heater hose


COST $$$$$ with shipping

Intercooler $100 Ebay cxracing( 5098)
pipe Kit $100 Ebay cxracing( 5098)
1.5" 45 elbow $17 Ebay siliconepros( 339)
1.5 plumbing pipe $15 hareware store
Greddy flange $12 Ebay wyntonm( 12149)
Welding $88 Look around there are many that can TIG weld.

[roh92cp]

With manifolds removed from compressor start openning up the 2 areas that the 3" pipe will be welded to. On the discharge side you must first take measurements and mock up a piece and use clay to assure it will fit under hood and around the fuel rails and sensors. Just use a 3" pipe like I did and clay to check fitment.

[roh92cp]

Here is how I went about cutting into the manifold. Don't be shy here just dive in, its not that hard. The first cut was with a drill so I could get my little jig saw in. I also used a carbide bur for aluminum alot of the medai removal and final shapping.

Here you need to remove and cut into the bolt hole boss to take advantage of the 3" pipe diameter. Also I don't have pics but the roof area where it say Kenne Bell on top was partly cut out and removed later for more flow.




Here on this end like I said you have mock up your 3" pipe cut it at an angle that will fit then scribe or mark with perm marker the area to be cut out. Then just cut man.


Here is the area of the roof that needs to be cut out between the bolt holes for more flow. As you can see the shaped 3" pipe is raised 3/8" above the manifold to take adavantage of the full 3" pipe area . Make sure you measure and use clay though it fit with my car.

[roh92cp]

Pipe fitment and shaping takes some time but its not that bad. I cut all my pipe with a radial arm saw with a regular 10" carbide blade, it works but be carful and go slow as it can grab the aluminum and throw it too. I also used another mider saw with a cutting wheel for some shaping and cutting smaller pieces. You can cut all the angles as well just go slow.

This pipe fabrication and fitment took the longest. The hard part was making sure the bend would clear the brake fluid cap area and of course it had to be angled down and also flatened and somewhat squared to fit the end of the KB discharge open area. I went slow and it took me about 3 hours to get it right. I can't remember the angles I cut but it wouldn't matter anyway as I'm sure there are slight differences from each vehicle and engine.


The next pipe inline is the S bend with the white rap that goes into the hole which is used for the windshield washer tank. Yes that means tank no more.


This is a pic of the inside of the drivers fender well. Take out the liner and its all exposed, tank and horn removed for installation of the next pipe that joins the S bend. Here you need a 45 degree silicone elbow and then a 90 deg L pipe. And below that one is another 90 deg L pipe that joins to the intercooler. Yes one side done.


Here is the front where it joins up to the intercooler right side of the pic.

[roh92cp]

Now for the other side intercooler (cold side) leading back up to the KB discharge start out from the intercooler with a U bend pipe.


Here in this pic from the top of the engine area you can see how the U pipe joins nicely with the intercooler and then ends up in position to lead up between engine and frame rail. I also had to trim the plastic shirt for the pipe in the end, its pulled out of the way now. Oh yeah the black box which is the charcoal canister has to be removed along with the metal bracket. Just unbolt it.



The next pipe here that connects to the U pipe is a 90 deg L that had about 3 inches cut off the short end. I would advise checking your own fitment here before cutting.




OK from this pic you can see the next pipe is the one next to the alternater and it is joined to the lower pipe with a 45 deg silicone elbow. This pipe is one half of a U pipe I cut in half. The other half was used at the beginning, driver side pipe to KB manifold. The one I spent 3 hours shaping.




The next pipe here has to be cut and you will have to make your own measurements to make it work and fit for your car. I cut it from a 90 degree L and both ends were cut. I shortend the straight end to leave me with enough room for the pipe that is welded to the KB discharge manifold. And the other end with the curve had to be cut to join to the pipe at its curve the one next to the alternater.




Here is how it should look from other angles




You can see her is used clay points on the pipe area to make sure I had hood clearance.

[roh92cp]

This is what it should look like in the end. If it doesn't do some more polishing :-) LOL.

Frankenstien Kenne Bell. Check it out.

[kbconv]

Pretty interesting setup.

Just one question though, how do you establish flow through the IC when both pipes are connected to the discharge? It looks like you would need a divider welded into the discharge to diverte the air comming out of the compressor through the IC and then the cool air would route to the lower part of the discharge.

Thanks

[tealstang67]

There is a plate welded in the discharge intake that diverts air flow.

[kbconv]

Gotcha,

Really great job and writeup! Congradulations!

[roh92cp]

There is a plate welded in the discharge intake that diverts air flow.

That is correct....

[roh92cp]

Aside from some dyno day SNAFU's I was happy with my numbers and tune. My car weight was 3140 at the scales that day and temp was @ 60 degrees. The Mustang dynamometer 1st run to 5800 rpm showed 385 rwhp and 524 ft-lbs torque something was amiss as my data log showed boost drop from 14.5 psi to 8 at 4300 rpm major boost drop on that run was a mystery as this had never happened before. Second and third run proved better as boost stayed flat at 14.5 psi. The last run resulted in 431 rwhp and 500 ft-lbs torque. The killer thing was my car made 460 ft-lbs torque at 2300 rpm. OK here goes the major SNAFU in all of this we never had any fan on the engine or intercooler during any of the runs I totally forgot and so did the dyno operator. I didn't even realize this until we had left the shop, what a bone head. My logs showed the ACT temps more than doubled to 130 degrees. Even with the belt slip and no fan I'm still pleased with how it performed total timing was 21 and my AF was 11.5 safe and sound. I hope this video works for you.
http://www.youtube.com/watch?v=h3i2eObmUck
__________________

[roh92cp]

Here is a little drive video to get the sound of the KB wine inside the car. Notice any time I excelerate I'm giving 1/4 to 1/2 throttle no traction in 1st second 3rd gear, that's what 460 ft-lbs torque at 2000 rpm does. Sorry for the crappy video I used my digital camera taped to my pass seat back and the roads are bumpy too. Anyway here ya go.
http://www.youtube.com/watch?v=SpZPEaRLa-A

[roh92cp]

I got a solid 17.5 PSI today with a 2.5 inch 6 rib pulley and belt, and no belt dust. I just couldn't wait for the 2.5 8 rib ASP is making me. I also am re-thinking this belt slip issue with the KB's and the route I was going, I'm not sure that belt slip really was an issue for losing boost. After talking with Carbinite Racing about the massive dust and belt destruction I found after using there pulley they now want me to use a manual tensioner. They are saying I need more tension on the belt and pulley to stop the belt destruction issue. I think this is a recipe for disaster as the KB drive system is not made to be direct drive so to speak. According to KB tech the friction drive system needs to have some slip to absorb shocks from the engine loads. The rotor timing and close tolerances are protected this way. Anyway once I will get the 8 rib 2.5" pulley I can compare with the 17.5 psi I got with the 6 rib. Its nice to know that the A2A setup can tolerate higher boost levels.

[roh92cp]

Here is a sneak peak of the early design of a new concept of an A2A intercooler manifold. It's a twist off and born out of my KB A2A project by a very talented mechinist and designer who I am working with on his design and idea of the A2A manifold. The project is right now at the mockup stage as you can see and some very minor adjustments are being done for fitment. The SCREWCOOLER as I I've been calling it will likely offer compatibility with the standard and Flowzilla inlets and will incorporate a bypass provision that still needs to be worked out. The discharge air works in a reverse order than the KB concept or even my A2A. Also this will be made to work with the all older 1.5,1.7, 2.2 and even the newer 2.1 Big Bore series compressors. I'm offering a sneak peak at this to gauge interest in sales. We would like you feed back on this to better be able to plan for the marketing ability of this project. I am very excited and could not be more pleased to have found a very credible and talented designer who could take this A2A concept to another level. Now it's up to pushrod crowd side of the Mustang nation to decide if they want to have a cool running KB like the modular motors have enjoyed.

[EDS50]

Subscribing.

[Vortech347]

if you could get a 2.4+ on there it would be awesome. While you are mocking stuff up I suggest building a dart t-shortblock.

[roh92cp]

if you could get a 2.4+ on there it would be awesome. While you are mocking stuff up I suggest building a dart t-shortblock.

Funny you say that> Last year I got a Fordstrokers Dart with all forged internals internal balanced 363. I will be putting in a Liquid cooled 2.8L new cam bigger 205cnc TW heads larger race intercooler with 3.5 in out and all new 3.5" pipe

[Vortech347]

if you could get a 2.4+ on there it would be awesome. While you are mocking stuff up I suggest building a dart t-shortblock.

Funny you say that> Last year I got a Fordstrokers Dart with all forged internals internal balanced 363. I will be putting in a Liquid cooled 2.8L new cam bigger 205cnc TW heads larger race intercooler with 3.5 in out and all new 3.5" pipe

You will make enough torque to make terminator and GT500 owners cry.

[roh92cp]

if you could get a 2.4+ on there it would be awesome. While you are mocking stuff up I suggest building a dart t-shortblock.

Funny you say that> Last year I got a Fordstrokers Dart with all forged internals internal balanced 363. I will be putting in a Liquid cooled 2.8L new cam bigger 205cnc TW heads larger race intercooler with 3.5 in out and all new 3.5" pipe

You will make enough torque to make terminator and GT500 owners cry.

Or change the rotation of the planet

[EDS50]

I loved watching your older videos when you were messing around on the street. We need to find a way to get all that power to the ground somehow

[roh92cp]

I loved watching your older videos when you were messing around on the street. We need to find a way to get all that power to the ground somehow

It's a funny thing how we enjoy the feeling of going sideways at will. I put some Nitto DR on last year 315/35 and found some traction and believe it or not missed be able to blaze the tires at will in 3rd that I know am upping the power level. Seems I'm always gauging the power and fun factor by how easy it blazes off the tires.

[EDS50]

I loved watching your older videos when you were messing around on the street. We need to find a way to get all that power to the ground somehow

It's a funny thing how we enjoy the feeling of going sideways at will. I put some Nitto DR on last year 315/35 and found some traction and believe it or not missed be able to blaze the tires at will in 3rd that I know am upping the power level. Seems I'm always gauging the power and fun factor by how easy it blazes off the tires.

Oh no doubt its fun as hell. Its when she breaks loose over 100 the pucker effect begins...lol