Helix | F56 Intercooler Testing - North American Motoring


Helix | F56 Intercooler Testing

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Old 09-16-2015, 05:49 AM
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Helix | F56 Intercooler Testing

We begin testing on our F56 Stepped Core Intercooler today. Marco G. has kindly lent us his tuned MCS for a battery of before-and-after tests on our prototype cooler. First step is to collect datalogs of the stock cooler performance, focusing primarily on street performance vs. dyno, since we can't replicate wind volume and velocity with the cooling fans in our dyno cell. We'll look at a number of data, primarily focusing on boost pressure drop and intake temperature drop. Luckily, it looks like we'll have a few consistent days of weather coming up so that will aid us in test condition.

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Old 09-16-2015, 12:00 PM
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you're right, you did take a nice shot of it. good luck with the work!
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Old 10-10-2015, 07:51 PM
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Any updates Eric? I still have my NIB SCIC I got on the group buy on M / A I want to trade in on one.
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Old 10-12-2015, 07:35 AM
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Originally Posted by vetsvette View Post
Any updates Eric? I still have my NIB SCIC I got on the group buy on M / A I want to trade in on one.
We're looking at a couple of design upgrades based upon testing. We were satisfied with the performance increase over stock, but Ryan our engineer has recently come up with a new concept that we really want to incorporate into this generation of intercoolers. This would be big, as in patent and trademark big, so we may make another prototype before going to production. We believe the time loss is worth it.
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Old 10-12-2015, 09:31 AM
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Thanks for the update Eric.

Subscribed...
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Old 10-16-2015, 09:14 AM
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Sounds interesting, will enjoy seeing what you bring to the table. After my track day this monday, Ill probably be wanting more power which needs a better intercooler for sure.
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Old 12-19-2015, 04:33 PM
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Any news on this, Helix?
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Old 12-20-2015, 07:20 AM
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Yes! We've 3d printed (in house!) our final prototype and tested it for fitment. Because we can now 3d print, our concept-to-production time will be greatly reduced. Here's the process.

-Measure a car in-house, and produce a design concept.

-build individual components of the intercooler in Solidworks. That includes building the core, row-by-row, shaping the end tanks, and building the ferrules, which on the F56 are a machined piece. On the older coolers, we could incorporate the ferrules in the cast end tanks, but with these, they need to be machined. The foundry can cast the tanks in such a way that we can directly machine the flanges into the castings.

-We virtually test the performance of the core and tanks, using Computational Flow Dynamic software, reducing pressure drop through the tank. This is where we spend a lot of time, designing and re-designing the shape of the end tanks. If you see intercoolers with welded sheet metal tanks, or cast tanks with the ferrules welded to them, they are inherently inefficient. We spend dozens of hours refining the 'scalloping' of compound curves in the end tanks.

-A new feature of our process for the F56 design is our ability to 3d print prototypes in-house. It reduces cost and time by a huge amount. It's been a big learning curve for us, but ultimately, we can go to production much faster and with less risk.

-We build prototypes for road datalogging and dyno testing. In the case of intercoolers, road logging is actually more effective than our dyno cell, since we don't have a wind tunnel associated with our dyno (if we had enough money for a wind tunnel, I'd be writing this from my island). We have already done this with one F56 prototype, and got good results, but not good enough. We had to re-think the design and start over. It meant a big delay in production, but ultimately, I think it will pay off. Nobody else does this. Nobody.

Finally, we go to production.

If you go to our FB page, we have posted some images of the printed tanks and some of the other work we are doing.
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Old 04-30-2016, 08:37 AM
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Is this intercooler still planning on being released? Haven't heard any news in a while
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Old 04-30-2016, 10:35 AM
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We will be displaying production pieces at MOTD. Everybody is welcome to come to our tent and check them out. The Intro Offer units are being finished as we speak and will ship shortly after we return from the Dragon. I'll keep this thread updated with delivery dates and more test data going forward.
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Old 04-30-2016, 11:12 AM
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Will this intercooler fit the F56 JCW? Seems the forge intercooler does not for some reason. At least that is what is posted on their website and waymotorsports.
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Old 05-01-2016, 06:51 AM
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We have not confirmed JCW fitment. It's on our list...
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Old 07-17-2016, 02:42 AM
MoJo4Twenty MoJo4Twenty is offline
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Had it installed yesterday and my F55 sounds awesome and an it just feels the intercooler belongs. I for sure can feel a difference as far as how the car pulls and accelerate. Good thing I had it installed before the Las Vegas leg of mini takes the states, the highs get to 108 so it gets hot. We will see how well it does ( I'm sure super awesome) I'm not into boost pressure and logging and all that stuff. I'm more a regular consumer. How much did I spend, and did I feel it was worth it. For now, it's a definite yes! You guys can read and research on your own. I for one am very happy with my choice.
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Old 07-17-2016, 07:25 AM
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Congrats MoJo. I had mine done at MOTD and have been very happy with it. The special pricing Eric gave us for pre-ordering was icing on the cake. I'm hoping to get some dyno time later this year to check the difference the I/C made with my JCW Tuning Kit and NM module.
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Old 07-17-2016, 08:48 AM
MoJo4Twenty MoJo4Twenty is offline
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Still no word on the S flow vetsvette? We pretty much have similar upgrades and I must say if my car is automatic, weight more and a few inches longer. Your F56 manual must be a little beast.
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Old 07-17-2016, 04:37 PM
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Haven't heard anything in a couple of weeks. Guess it's about time to pester Josh again. I'm pretty happy with my car as it sits, but I still want the few more HP that the intake will provide. Are you gonna try to get your splitter installed tomorrow?
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Old 07-17-2016, 04:55 PM
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Yes! Already have my guy pencil me in for 2 tomorrow! It was next day air and scheduled for a commit time of 10:30 I really just want everything mounted and secure ready for Tuesday night. I think all we have left is maybe a down pipe of sorts but not too sure. For now I'll safe a bit for the tires once the wheels come in very shortly.
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Old 07-17-2016, 05:10 PM
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Good for you. I won't have access to the lift until next weekend so that's when mine'll get installed. A Down pipe is in my future, but not until my warranty runs out. I'll be adding a Manic Tune when I install the DP. But, I still have another 55K+ miles on my warranty, so I'm sure they'll have a tune available by then. Just have to be happy with what I have until then.
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Old 07-17-2016, 05:24 PM
MoJo4Twenty MoJo4Twenty is offline
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That good all warranty. My issue is warranty, as well as California emission laws. They regulate everything. We can't even buy a gallon of plastidip in this state. I'm looking into a local tuning shop (maybe around the warranty cut off time) ecu tuning group. Dinan has a piggy back but the real deal just makes me drool. Ohh the possibilities. Im surprise how much I've done considering I was going to keep it stock. Lol! It gets out of control real fast.
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Old 07-17-2016, 05:49 PM
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Another reason I never looked back when I left CA in '84.
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Old 07-25-2016, 09:32 AM
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Guys
I have a question for you on the inter cooler. Does your dealer support this if you have a warranty claim? I am just concerned about some service writer voiding a claim as this is my daily driver and I do 2,500 miles a month.
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Old 07-25-2016, 12:58 PM
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The only way they would know is if they pulled the front end off the car. There's no problem I can think of that could be blamed on an improved intercooler. I've been running mine since 5/13 with no ill effects. It's coming in handy with these high 90's temps we're having lately.
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Old 07-27-2016, 06:29 PM
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Originally Posted by camptown
Guys
I have a question for you on the inter cooler. Does your dealer support this if you have a warranty claim? I am just concerned about some service writer voiding a claim as this is my daily driver and I do 2,500 miles a month.
Per the Magnusson-Moss Warranty Act of 1970-something, they cannot deny warranty coverage for something not directly related to your mom-OEM parts.

MINI North America just recently settled a class action suit over this; they had to send letters to all owners explaining that they had acted illegally in telling owners that use of non-MINI parts or service providers would invalidate warranty.
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