Double Bypass Intercooler System

NotSatisfied

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Just finished my double bypass setup. This is probably the most efficient setup you can get.


Ran into a snag with clearance on the fog lamp housing on the passenger side but I’ll figure it out by either bending the bracket or spacing the pump towards the rear of the car.

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The Harpell Fab stuff is so nice!

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01yellercobra

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It might be worth looking into restrictors between the tank and Y fittings. I think Ford put them in to keep more coolant going through the system and less through the tank. Food for thought.

I'm curious how it works for you though. I've been wanting to try thing, but can't think of how I want to run the lines.
 
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GodStang

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It might be worth looking into restrictors between the tank and Y fittings. I think Ford put them in to keep more coolant going through the system and less through the tank. Food for thought.

I'm curious how it works for you though. I've been wanting to try thing, but can't think of how I want to run the lines.

Glad you found this. While my setup is a bit different it may be worth it to try.
 

NotSatisfied

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That's well done. Do you mind sharing with us the Y fittings and other odds ends used in case folks want to look into it?
You will need a Cobra Engineering Crossover Delete

Two of These

Two of These

Some of this tube

 

DCguy

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Cool thanks - I believe I remember you're on 1in lines so, for those using 3/4in hose, this one will probably work:

TH Marine Barbed WYE Y-Fitting, 3 Way, 3/4” Hose p-# Y-750-DP
 

DCguy

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3/4” lines are holding you back big time.


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Actually not by much…marginal amount at best. A guy on the fb pages did a pretty comprehensive flow comparison on pumps, lines, HE’s, IC cores etc. 1in over 3/4in was like 2-3gpm it wasnt much…..i cant recall if it was a trunk tank or not. Not everyone has the VMP core so the 1in lines will have to wait. If youre lower boost like 16-20psi i doubt 1in lines would make a huge difference either way….higher boost maybe.
 

NotSatisfied

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Actually not by much…marginal amount at best. A guy on the fb pages did a pretty comprehensive flow comparison on pumps, lines, HE’s, IC cores etc. 1in over 3/4in was like 2-3gpm it wasnt much…..i cant recall if it was a trunk tank or not. Not everyone has the VMP core so the 1in lines will have to wait. If youre lower boost like 16-20psi i doubt 1in lines would make a huge difference either way….higher boost maybe.

Yes Jonathan Talley did. He flowed my car in 3/4” lines, it flowed 12.34 gpm. My car is probably now flowing 18gpm. The Intercooler is the restriction on these cars.

I get it about not having a manifold adapter to accommodate 1 “ lines but you can do a 1” to 3/4” coupling just before the Intercooler and have everything else 1”.

To say 1” lines aren’t that much better than 3/4” is foolish.


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DCguy

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Yes Jonathan Talley did. He flowed my car in 3/4” lines, it flowed 12.34 gpm. My car is probably now flowing 18gpm. The Intercooler is the restriction on these cars.

I get it about not having a manifold adapter to accommodate 1 “ lines but you can do a 1” to 3/4” coupling just before the Intercooler and have everything else 1”.

To say 1” lines aren’t that much better than 3/4” is foolish.


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I didn't say "they aren't much better".......I said the difference was marginal, which it is. Its all relative to the setup, what compression vs boost you're running, what are the IAT and overall heat the system is generating, what kind of pump, trunk tank vs. engine tank, overall capacity of the system, where the restrictions are, etc.......There's a lot of variables at play here......in some cases too much flow can be a problem as well. Bigger is not necessarily always better all the time. I would say not being able to distinguish between the two is foolish.

I understand you're happy with your setup and glad you found / fixed your issues as you were on the verge of selling your car. I was one of the many giving you advice on how to do so....remember, some of us have been in the 03/04 cobra game a lot longer than you. So, you don't need to work so hard to justify your setup by calling me foolish. I'm on your side.

I'm just letting people know that your comment of "3/4in lines are holding you back big time" is 100% nonsense.
 

NotSatisfied

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I didn't say "they aren't much better".......I said the difference was marginal, which it is. Its all relative to the setup, what compression vs boost you're running, what are the IAT and overall heat the system is generating, what kind of pump, trunk tank vs. engine tank, overall capacity of the system, where the restrictions are, etc.......There's a lot of variables at play here......in some cases too much flow can be a problem as well. Bigger is not necessarily always better all the time. I would say not being able to distinguish between the two is foolish.

I understand you're happy with your setup and glad you found / fixed your issues as you were on the verge of selling your car. I was one of the many giving you advice on how to do so....remember, some of us have been in the 03/04 cobra game a lot longer than you. So, you don't need to work so hard to justify your setup by calling me foolish. I'm on your side.

I'm just letting people know that your comment of "3/4in lines are holding you back big time" is 100% nonsense.


I just want to clarify, I’m not disrespecting you. You said marginally better, that’s simply not true. I’m not working hard to justify, I’m just stating my opinion; I have talked a lot with Jason (DOB) and many others. I have done ALOT of research and your right about variables but fundamentally this setup is ideal.

Sorry you were offended, I was just disagreeing with you (and that’s ok!)

It’s not fair you bring up me wanting to sell my car and the issues I have had to deal with. That has nothing to do with this. I’m not saying I’m an expert now.


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FleeMan

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Internet really sucks when you're trying to get your point across and it gets misunderstood.

I personally am glad that dudes that have the knowledge want to share it and also glad you are reaching the end goal with your car which is for it to be reliable. Keep doing what you're doing, listen to other people and do your research and enjoy your car.
 

94slowbra1

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Glad you got it figured out. What i/c core are you running?
Curious why you needed the bypass? If it's been mentioned elsewhere I apologize. Also interested in the results once you get some data. These cooling threads are always interesting to follow.
 

NotSatisfied

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Glad you got it figured out. What i/c core are you running?
Curious why you needed the bypass? If it's been mentioned elsewhere I apologize. Also interested in the results once you get some data. These cooling threads are always interesting to follow.

It’s a VMP unit. Bypass calms the velocity of the water and prevents aeration.


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94slowbra1

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Got ya. How much fluid does that Harpel tank hold?
Just a word if advice, run a little coolant in that system. It will help keep everything lubed and prevent corrosion. And keep an eye on outside temps with just water, you don't want to burst the i/c. I know h-town doesn't get below freezing often but just incase. I'm in FL so I run mainly water too but had to load up on coolant a few weeks ago when we had a cold snap
 

NotSatisfied

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Got ya. How much fluid does that Harpel tank hold?
Just a word if advice, run a little coolant in that system. It will help keep everything lubed and prevent corrosion. And keep an eye on outside temps with just water, you don't want to burst the i/c. I know h-town doesn't get below freezing often but just incase. I'm in FL so I run mainly water too but had to load up on coolant a few weeks ago when we had a cold snap

So true.

Yeah it’s a smaller tank.

When I bought the car it had water only and it busted during transport in March. So if I see the forecast get below freezing I literally just drain and blow the system out.

This was mine and it flooded the motor.
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NotSatisfied

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We’ll just an update here… unfortunately I had to cut the passenger “wing” off the MAF crash bar. If I could do it over again. I would just get a driver side wing (catch can) and not both sides. Honestly the position of these wings and the factory fog lamps, leaves little room to do anything. Anyways. I ended up mounting to the core support and everything is perfect now. I just need to tidy things up, I’m out of zip ties.

I’m happy.

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JCDriller

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So the point of this is to slow down the water, giving it more time to exchange heat and reduce bubbles in the system? Is this correct? Did you get a baseline measurement on IATs and intercooler fluid temps before you did this? Would be interesting to know the difference this makes. Just a shame all the additional hosing clutters up such a beautiful engine bay. But form over function, if you can’t enjoy it because it’s getting hot, so be it.

Thank you for sharing.
 

01yellercobra

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So the point of this is to slow down the water, giving it more time to exchange heat and reduce bubbles in the system? Is this correct? Did you get a baseline measurement on IATs and intercooler fluid temps before you did this? Would be interesting to know the difference this makes. Just a shame all the additional hosing clutters up such a beautiful engine bay. But form over function, if you can’t enjoy it because it’s getting hot, so be it.

Thank you for sharing.
It's to keep the coolant in the tank from cavitating. The goal is to move the coolant as fast as possible. The problem with that is the tank can foam and cavitate because of the inlet side. Foam doesn't pump very well and thus kills cooling capability.

I went through that when I installed the GT500 pump. And it's why Ford went with the bypass in the 13/14 GT500.
 

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