Drivetrain Helix Stepped Core Intercooler - Real testing, Real results
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07-23-2008, 03:21 PM
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Helix Stepped Core Intercooler - Real testing, Real results
Updated initial post with more info
Installed
Helix R56 Stepped Core Intercooler
Core Design
Prior to the 335i and the R56 Mini stepped core design you had the option to either go Taller or thicker with the cores. In my design process I measured the captive areas in the front of the bumper in both depth and height and went about designing an intercooler that took up all of this area. The end result is an intercooler with 53% more frontal area as well as 50% more core volume. now about the core, we were not constrained to an off the shelf core in regards to ambient and internal fin count as we custom spec'd the core to this application. the core in the Helix FMIC is a single unit stacked up to our specifications in regards to ambient and charge row height and internal and external fin count. since our core has more volume I could increase the internal fin count to remove more temperature and still meet the targeted air flow and pressure drop for this application. as you see by the AIT data logs the intercooler works amazingly well.
Endank design- all endtanks are not created equally, air likes to flow in a smooth curved radius as you can see the Helix FMIC has rounded endtanks that are cast.
Install:
Fits in stock location- YES
requires no cutting,removal and/or permanent modification- Yes
Design:
More core volume than stock- Yes 50%
More Ambient face than stock- Yes 53%
More charge rows than stock(5)- Yes 12
Bar and Plate construction- Yes
Performance:
STOCK turbo outlet temperature 245 degrees F(estimated using a 65 degree ambient and 65% compressor efficiency at 15 psi
Temp drop from 245f to 111f(peak temp) in 4th gear run = -134f degree drop
HELIX TEST turbo outlet temperature 253 degrees F(estimated using a 71 degree ambient and 65% compressor efficiency at 15 psi
Temp drop from 253f to 89f(peak) in 4th gear run = -164f degree drop, 21% better cooling than stock
AIT temp- 30 degree drop over stock
pre and post intercooler temp drop- 164 degrees F
Intercooler efficiency- 80% - 21% improvement in efficiency over stock(59%)
Core pressure drop spec is .5psi at 250hp(400cfm) airflow
Core Design
Prior to the 335i and the R56 Mini stepped core design you had the option to either go Taller or thicker with the cores. In my design process I measured the captive areas in the front of the bumper in both depth and height and went about designing an intercooler that took up all of this area. The end result is an intercooler with 53% more frontal area as well as 50% more core volume. now about the core, we were not constrained to an off the shelf core in regards to ambient and internal fin count as we custom spec'd the core to this application. the core in the Helix FMIC is a single unit stacked up to our specifications in regards to ambient and charge row height and internal and external fin count. since our core has more volume I could increase the internal fin count to remove more temperature and still meet the targeted air flow and pressure drop for this application. as you see by the AIT data logs the intercooler works amazingly well.
Endank design- all endtanks are not created equally, air likes to flow in a smooth curved radius as you can see the Helix FMIC has rounded endtanks that are cast.
Install:
Fits in stock location- YES
requires no cutting,removal and/or permanent modification- Yes
Design:
More core volume than stock- Yes 50%
More Ambient face than stock- Yes 53%
More charge rows than stock(5)- Yes 12
Bar and Plate construction- Yes
Performance:
STOCK turbo outlet temperature 245 degrees F(estimated using a 65 degree ambient and 65% compressor efficiency at 15 psi
Temp drop from 245f to 111f(peak temp) in 4th gear run = -134f degree drop
HELIX TEST turbo outlet temperature 253 degrees F(estimated using a 71 degree ambient and 65% compressor efficiency at 15 psi
Temp drop from 253f to 89f(peak) in 4th gear run = -164f degree drop, 21% better cooling than stock
AIT temp- 30 degree drop over stock
pre and post intercooler temp drop- 164 degrees F
Intercooler efficiency- 80% - 21% improvement in efficiency over stock(59%)
Core pressure drop spec is .5psi at 250hp(400cfm) airflow
Installed
Last edited by Ralph@Helix; 01-05-2009 at 08:47 AM. Reason: Charts didn't show up 1st go-round...
#2
07-23-2008, 04:02 PM
The Helix Stepped Intercooler design has a bigger frontal ambient face combined with thicker-than-stock core that seals off to the radiator fan/shroud. The cast end tanks have factory mounting points and factory charge pipe angles. The core of the Helix Stepped Intercooler has increased fin density and will flow 250 horsepower with only a 0.5PSI pressure drop. That translates to cooler intake temperatures with a slight reduction in pressure.
Here are two graphs showing you the results from the data logging of our stock R56, then with only the Helix Stepped Intercooler installed. We think you will be impressed with the performance improvements!
Both graphs compare intake manifold temperatures between the stock intercooler (dang stock piece looks like a small toaster oven!) versus the Helix Stepped Intercooler (jumbo air-cooling surface area!). The first graph shows the intake air temperature changes as we performed a 3rd gear roll-on at wide-open-throttle. The second graph shows the intake air temperature changes as we performed a 4th gear roll-on at wide-open-throttle.
With this intercooler, under high-performance driving your R56 will be less prone to heat-soak, leading to increased performance and sustained power. The Helix Stepped Intercooler will be a perfect upgrade especially combined with a GIAC reflash.
Here are two graphs showing you the results from the data logging of our stock R56, then with only the Helix Stepped Intercooler installed. We think you will be impressed with the performance improvements!
Both graphs compare intake manifold temperatures between the stock intercooler (dang stock piece looks like a small toaster oven!) versus the Helix Stepped Intercooler (jumbo air-cooling surface area!). The first graph shows the intake air temperature changes as we performed a 3rd gear roll-on at wide-open-throttle. The second graph shows the intake air temperature changes as we performed a 4th gear roll-on at wide-open-throttle.
With this intercooler, under high-performance driving your R56 will be less prone to heat-soak, leading to increased performance and sustained power. The Helix Stepped Intercooler will be a perfect upgrade especially combined with a GIAC reflash.
Pricing??
#5
07-23-2008, 07:48 PM
#6
07-23-2008, 09:25 PM
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07-24-2008, 08:15 AM
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#10
07-24-2008, 08:43 AM
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#12
07-24-2008, 11:54 AM
Reply to sizing and pricing
The Helix Stepped Intercooler is a direct fit bolt on - installation will involve removal of the R56's front air dam, then removal of stock intercooler. Next secure the new intercooler, and remount the front air dam. No cutting, drilling or other modifications needed. It's a clean fit. No ECU flags or error codes...just cooler intake air.
It gives a slick look too, whether you keep the stock lower air grill (just a slight hint of something lurking beneath your R56 MCS) or use an aftermarket one that shows more of the intercooler!
We did not dyno test, therefore don't have HP/Torque data...Our data did clearly show much cooler intake manifold air temperatures, especially from mid- to high-RPM ranges. The Helix Stepped Intercooler will make little HP difference as a single aftermarket improvement, but is valuable when adding increased boost pressure! Other valuable benefits from the extra cooling for your R56 include: experiencing less HP power-drain on hot days (summer), cooler engine temps, and improved cylinder detonation thresholds (meaning that the R56 ECU will not retard ignition timing as soon).
This was our final testing on the Helix Stepped Intercooler, and pricing will be available shortly...Look out for our next announcement! Thanks for checking it out!
It gives a slick look too, whether you keep the stock lower air grill (just a slight hint of something lurking beneath your R56 MCS) or use an aftermarket one that shows more of the intercooler!
We did not dyno test, therefore don't have HP/Torque data...Our data did clearly show much cooler intake manifold air temperatures, especially from mid- to high-RPM ranges. The Helix Stepped Intercooler will make little HP difference as a single aftermarket improvement, but is valuable when adding increased boost pressure! Other valuable benefits from the extra cooling for your R56 include: experiencing less HP power-drain on hot days (summer), cooler engine temps, and improved cylinder detonation thresholds (meaning that the R56 ECU will not retard ignition timing as soon).
This was our final testing on the Helix Stepped Intercooler, and pricing will be available shortly...Look out for our next announcement! Thanks for checking it out!
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07-24-2008, 01:29 PM
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07-24-2008, 02:56 PM
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#17
07-24-2008, 03:32 PM
I would love to have a better flowing/cooling FMIC as (1) I live in NE TX so 90-100F right now (2) I have the Unichip so can take advantage of the better flow & cooling capabilities.
This is not a "bling" item for me, it is a functional item so must be worth buying.
At $700 a new FMIC is seriously overpriced and more for someone almost 1/2 my age with $$$ to burn on "bling"
Last edited by ukaussi; 07-24-2008 at 04:16 PM.
#18
07-24-2008, 03:59 PM
Never considered getting an intercooler, but like what Helix has done with this. If the price was cheaper than the other outrageously priced IC's...then you'd really have me on board.
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07-28-2008, 09:04 PM
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07-28-2008, 09:22 PM
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07-29-2008, 11:36 AM
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#24
12-18-2008, 06:27 AM
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The Helix Stepped Core Intercooler is now available folks!
No need for a group buy since we're offering it at an introductory price of $679
http://www.helix13.com/mini/products/engine-intake
No need for a group buy since we're offering it at an introductory price of $679
http://www.helix13.com/mini/products/engine-intake
#25
12-18-2008, 07:55 AM
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