Sid:
I took a section of model airplane strut, about 1/4" on the short axis, 3/4" on the long. They look like this:

I then cut it perpendicular to the long axis at the maximum width to get two sections. I got a parabolic section for the front of the IC (inlet) and the long-parabolic section shown in the photo above for the rear of the IC (outlet). This seems to be the optimal use of the sections, and although it took quite some time to get the JBWeld onto the IC, it all hardened up very well and very clean. Those suckers are not going anywhere, anytime!
If people are having a hard time getting these sections, I can get them for you. They are 3" long, and will require shipping in a tube. You'll have to figure out how to cut them. They cost a little under $7 including NM tax, which I have to pay.
PM me if you want further information. I searched the web and had a very hard time finding this tubing!! Weird.

 

That's what I've been looking for

 

More data: This morning ambient was 37F. The intake system approach (IAT - ambient) was 8F and the temperature drop across the DFIC was 130F. Now that's performance by my standards.
I've decided that the entire system performance is what counts, not just TE. Of course, MAF is what produces HP, but I'm not measuring pressure at the moment.

 

Good numbers, Phil. That works for me.
Did you mean MAP?

 

I think he meant MAF alright - Mass Air Flow.

 

That's what I thought, but I guess he threw me off when he said he wasn't measuring pressure. I think it's time for bed.

 

Good ole Wiki:

http://en.wikipedia.org/wiki/MAP_sensor

Could go either way I suppose...

 

True.
Speaking of MAP(sensor), why does the MCS have two?

Number 12 in this pic...


Number 9 in this pic...

 

Well, if I had to guess, for some kind of delta or differential check between those two locations...

 

That makes sense, Tony. It just seems odd to me as they are not very far apart.

 

#12 measures before supercharger pressure (acutely vacuum) like a normally aspirated engine, to give the ECU a reference along with the temp sensor thats before the supercharger. The ECU can use a lookup table it has to compute what the Mass Air Flow (using temp and pressure) into the intake is (what the volume of air that the engine is taking in). We don't have a real MAF sensor, like some other cars, which does this directly. This is good. Lots of the cars try to go to a MAP sensor rig and eliminate the MAF sensor when they go for the big HP. gains.

 

Yes, I did mean MAF--since Dr O has emphasized air mass as being the real measure of how much "power making stuff" we are delivering to the cylinders. MAP and temperature and a lookup table allow the ECU to figure out MAF, but it's not something we do while we're driving along (well, I don't...even though some might imagine I do!)
So, bottom line, a good MINI IC lowers IATs and doesn't lose too much pressure, to achieve the highest MAF possible.

 

IN the pictures from RealOEM, MAP #12 in the first picture measures atmospheric or barometric pressure since it sits out in the air at the end of the engine. MAP #9 in the second figure measures absolute pressure at the intake manifold just after the IC. The level of boost or vacuum is calculated by subtracting the #12 reading from the #9 reading. Eg here in Albuquerque (alt 5000ft) #12 usually reads 12.1psi +- .2, and at near full boost WOT, #9 reads about 25psi, giving me about 13psi boost with a 15% reduction pulley.

cheers,

 

That's good to know, Phil. Thanks for posting.

 

Hey Phil...how's the foamy experiment coming along?

 

Well, the 'foils are cut lengthwise and straight and flat--but the foamy core did not set/harden. It must use oxygen or air to complete what I thought was a chemical reaction, so I am trying an alternative.
To catch others up, I am fabricating some leading edge and trailing edge 'foils for Sid's DFIC, and he suggested I fill the streamline tubing with expanding foam to make cutting and mounting easier. Unfortunately it did not set hard in the center of the tubes, just the ends. It still cut well, but that's more a function of the tool I'm using to cut it rather than any support provided by the foam. Now I just have a gooey mess inside the 'foils.
I will post photos when I come up with a solution (play on words, there, you know...)
cheers,

PS I took my car to the local MINI dealer and asked the head technician (we used to call them mechanics...) to take it for a spin. I was very pleased when he came back saying it was the fastest MINI he'd ever driven. Woohoo!

 

That's because he's never driven my car!

Seriously, are you guys using the leading edge of the foil on the inlet side of the DFIC to help the charge air or just on the front face?

 

Dr: Give us a list of what devices you have and what sensors they record/display. Sounds like a lot of fun.

 

Of course! Actually, I doubt my car is particularly fast compared to most of the MINIs here on NAM...but remember, most of the cars the Tech drives are stockers, and I doubt he's been offered the "no limits" keys to many of the modified cars around here. That said, Albuquerque has about 2 highly modified cars, and mine's one of them, so there's not much to brag about 'round here.
Partsman: I didn't install the 'foils internally, as they are extremely difficult to glue given they are hollow sections--there's just not enough room to make a clean install. I'm sure they would not hurt on the inside, and may clean up some turbulence caused by the funky plenum chambers/end tanks on the DFIC, but I wasn't willing to risk getting JBWeld all over the cooling fins just to get a couple of 'foils in there. Sid hasn't tried the install yet, as I still have his 'foils!

 

I'm an amateur when it comes to telemetry. I am simply measuring 5 temperatures on the intake path:
1. ambient around the car (measured by the car's OBC)
2. air box temperatures (measured by a digital probe)
3. post-SC, as the air enters the IC (measured by a probe connected to a VR IC dual temperature gauge)
4. post-IC, at the exit plenum of the IC (measured by a probe connected to the same VR IC temperature gauge)
5. IAT measured in the intake manifold, by a sensor used by the car's on board computer (OBC) (displayed by a ScanGaugeII.)

It certainly is fun, and I would love some logging capability, but I will have to wait for that (hint hint )

 

Phil...even if the foam experiement doesn't work out (I'm still puzzled why it didn't cure all the way through), I was going to fill the half sections with bondo and file flat then use that surface for bonding to the core...

 

I figured that the tech has probably only driven "virgin" MINIs, so to him, your car is a monster.
To me, using the half-rounds on the inlet side was just as important as the front face, if not more so.
I have almost equalized the pressure differential across the core of the DFIC using "other mods". My goal is to get the same boost readings from both the inlet and outlet bungs.

 

Would you be willing to sell some of these? PM me!

 

I'm not sure who you're asking, me or DrPhil.

https://www.northamericanmotoring.co...3&postcount=71

 

I totally agree! Of course, if the 'foils could be added before the endtanks are welded on we'd be in heaven (and dead?)
The "other mods" to reduce pressure drop across the IC sound *very* interesting...! I see very high temperature drops across the IC (I've measured 100+F often and as high as 130F), so combining this with low pressure loss makes the IC a very nice part of the inlet air pathway!

cheers