TyrolSport R55/56/57 Upgraded Front Mount Intercooler

Attention NAM members, we think you will be excited to learn about our new upgraded Front Mount Intercooler for the R56. We have spent the last two years developing, testing and refining this intercooler to ensure that we have created a truly exceptional product. Read through our testing below and let us know what you guys think. We look forward to hearing your feedback/criticisms/praises .

Thanks again!

TyrolSport



The TyrolSport MCS FMIC provides an excellent balance of performance, design, and installation ease to really enhance your R55/R56/R57 Mini Cooper S. Our intercooler uses a unique thin core design to maximize cooling characteristics. It will yield power gains from 10-18 HP/12- 20 ft lbs torque to the wheels, depending on your level of modifications. Our design has incorporated hundreds of hours of research and development and over a year of vigorous testing on the street, track, and dyno. Our intercooler can be installed in a few hours with basic hand tools and almost no trimming. This intercooler is designed for the enthusiast who does not want to compromise and wants the best product on the market.

Additional features include:

Made in USA
Utilization of factory mounting points
Hundreds of hours of dyno and track testing
One year warranty against product defects





Our first test was to take our new 2009 R55 Mini Clubman S to the track to really put it through its paces. We used Watkins Glen International in July and August, the most grueling track in the Northeast, at the peak of the summer heat. We realized immediately that the R55/R56/R57 is a fantastic platform for driving on the street, autoX, or track. A combination of firm brakes, excellent transient response, and good power made it very fun to drive.

Without TyrolSport FMIC:



However, within 5 laps we began noticing a drop in power…..where was the 170hp that Mini claims? Lost to the laws of physics appeared to be the answer. The stock intercooler couldn’t keep up with a small turbo spinning its heart out. Here is a video of what we found when analyzing the turbo speed:





All kidding aside, after a few cooldown laps, the power would return, only to be lost again after a couple of hot laps. We were not going to let heatsoak ruin our fun…..we wanted all of the power we paid for all of the time! Now we were on a mission. We went back to the shop and measured the size of the stock intercooler. The actual dimensions are 22” length x 3 3/8” height x 2 ½” wide. This gives us a core volume of 185.625in³. Not enough to prevent heatsoak on an R55/R56/R57 with any amount of modifications.

With TyrolSport FMIC:



TyrolSport has developed an excellent reputation for developing top quality, easy-to-install intercooler replacements for just about every turbocharged VW and Audi from 1998 on. We set to work on improving the intercooler design using our proven methods. Our main goals when designing a new product are to develop a product that is a premier quality, true performance bolt-on. We do not expect our customers to compromise, and we design our products to be the best available for a given application. Our goals for this project followed our standard guidelines when developing an intercooler:

1. Proven horsepower and torque gains vs. the factory intercooler.
2. Use of premier quality bar and plate intercooler cores.
3. Easy to install with minimal trimming and use of factory mounting points.
4. All research and development, prototyping, and manufacturing in the USA.
5. Strong customer support with a product warranty of 12 months/unlimited mileage

Our traditional approach has been to work within the space constraints offered by the factory. We realized immediately that for the Mini, we would have to work hard if we wanted to create a truly exceptional product. We started by test-fitting various core shapes and sizes to understand the optimum intercooler that would fit. After many months of prototyping, shop fitting, dyno and road testing, we finalized a design which produces excellent power, eliminates heatsoak, and is easily installed with almost no trimming.





The most obvious question that comes to mind is why did we choose to a core with a large face area and thin cross-section? We found that a large face area and thin core worked much better in the Mini versus a smaller, thicker core which would fit in the stock location. We have found that this design not only dissipates heat at an incredible rate but we could not get this intercooler to heat soak. On top of that, the pressure drop is a minute .5@20psi. This intercooler has the perfect volume for an engine which will make anywhere from 220 to 300HP. Another advantage to our intercooler design is that it is a direct bolt-in with extremely minor trimming involved. This intercooler is a true bolt-in design, using the factory mounting points. It can be performed by even a novice enthusiast with basic tools.

TEST CAR
•2008 R56 Mini Cooper S

•6 speed Manual

•Revolution Mini Works Software

•Ragazzon down pipe

•Milltek cat back exhaust

•Alta boost pipes

TEST CAR
•2009 R55 Clubman S

•6 speed Manual w/ factory LSD

•Stock software

•Stock intake/exhaust

TEST CAR
•2009 R55 Clubman S JCW

•6 Speed Manual

•Factory JCW software

•Stock JCW intake & exhaust

For the purpose of the intercooler testing, please remember that the absolute numbers shown on the dyno are not relevant. We are looking for, the deltas, or relative changes in performance that result from upgrading the component. While your R55/R56/R57 MCS may dyno higher or lower than our project car at a different dyno facility, you can expect similar relative gains when adding our UGFMIC kit to your car.

At TyrolSport we are firm believers in back-to-back dyno tests, using the same facility on the same day, so that we can eliminate weather and dyno variance. The testing of both the stock and TyrolSport intercoolers was completed in one day under the following conditions:

1. Get car to operating temperature on the dyno, 100C water temp
2. Make 5 dyno pulls on the stock intercooler with one minute of cooldown between runs.
3. Remove stock intercooler, and bolt on TyrolSport UGFMIC with car still strapped to the dyno
4. Repeat process again for TyrolSport UGFMIC to verify initial runs

•Dyno fans were used on all runs.
•The bumper cover was put in place when testing each intercooler.





While on the dyno, we data logged RPM, Intake Air Temp, Timing Advance, Boost pressure and Coolant Temp to verify the performance benefits and differences between the two intercoolers. All of the information provided is from real-world testing, with no alterations, tricks or gimmicks.
Installing the TyrolSport UGFMIC showed immediate and clear results. Upon bolt-on, with absolutely no other changes, power increased by 10 WHP over stock on a cold run. With these results from the start we knew this intercooler would be a true performer.. Let’s take a look at the graphs:












After 5 back-to-back runs you can see the huge amount of heat soak that the stock intercooler exhibits throughout the RPM range. Our test car gained a maximum of 16 WHP, and averaged 14.5 WHP/15.6 WTQ from 2000-6000 RPM. During our testing procedures we want to understand the “whys” and not take an improvement on face value. We want to investigate further and verify that we are gaining power in a safe and repeatable manner. This is why we log the cars data blocks. The primary reason to have an intercooler is to lower the temperature of the compressed air entering the engine. To test this we looked at our logs which we recorded with every dyno run. What we found correlated with the dyno runs:





This graph demonstrates the actual air intake temperatures during the dyno runs for each intercooler. You can see how the air intake temperature rose dramatically on the stock intercooler after 5000rpm. The stock intercooler could not return to its baseline temperature even with a one minute cooldown. The TyrolSport UGFMIC, however, is able to stay cooler after four back-to-back runs than the stock intercooler after only one run on the dyno. Here is a graph of the above data averaged:





The average temperature difference is a drastic 25 degrees Celsius, with a maximum difference of 33.5 degree Celsius or anywhere between 77 and 92 degrees Farenheit cooler after four runs.

STREET TESTING
Once our dyno testing was completed, we ran highway data-logging to make sure that the upgraded intercooler exhibited “real-world performance gains”. Again, all of our data was acquired on the same day, in the same exact weather conditions, using the same route of travel. It is always our goal to minimize the variability in testing, to understand the true performance gains (or losses!) of an aftermarket product.





All runs were done in 3rd gear, starting at 2000rpm, and then going full throttle to 6500. The car was allowed to decelerate in gear until 2000rpm, at which point we went full throttle to 6500rpm again. This process was repeated until four full throttle runs were completed for each intercooler. This would represent real-world acceleration from approximately 35mph to approximately 95mph. The runs were conducted in opposite directions to negate wind direction. We eliminated the first run for consistency. Coolant and Intake Air Temperature were monitored so that it would be the same for each unit at the beginning of the testing. Information from our testing was gained using Bavarian Technic diagnostic software.





The two main areas which would confirm our data on the dyno are Intake Air Temp and Ignition Timing Advance. Once we logged our runs we sat down and analyzed our findings.
The first thing we will look at is the Intake Air Temp. Our initial tests show the immediate power gain over the stock FMIC.








































The retail price is $1095. We have an introductory group buy which was just opened in the group buy forum.

A word on quality and pricing:

All TyrolSport products are designed and manufactured in the USA, using domestic materials. Our commitment to you is to provide the best quality, testing, and support for products that provide true performance benefits for your car. We stand by the quality and functionality of our product. We also guarantee our intercoolers against defects for one year with unlimited mileage usage. Our R&D efforts allow us to bring superior products to market which can be appreciated by true enthusiasts. We hope you enjoy your car, and our products. Thank you very much as always for your support, and happy motoring!

 

Still have this intercooler and might I say, its awesome and the build quality is great. Much more surface area to dissipate heat

 

I remember this from way long ago, glad too see you guys finally have it out to the masses....Really love how "outside the box" it is!

 

this intercooler looks awsome!!!!

 

I could cool the charge-air from a Detroit Diesel Series 60 with this

 

I want one!!!!!!!!!!!!!

 

This is very interesting.

Bit steep though.

 

looks like it performs great - however, i would not have it on my car unless it came in black.. It looks funny through the grill while bright.

You don't have to listen to me though since I already have an aftermarket FMIC and won't be buying another one.

 

Is there any plans on making the core section a little longer? Looks like the end tanks could be shrunk down a bit to fit a larger core. That should help cooling even further.

Thanks,

Chris.

 

I think the picture makes it look brighter than it actually appears in real life. Anyone can paint the intercooler black, but it will reduce efficiency.

 

We experimented with a wider core and smaller end tanks. Two issues resulted:

1) Flow to the top end of the core was reduced dramatically(because of the pinched ends), resulting in higher IATs on average.

2) Significant trimming was required for it to fit

 

that looks really great

 

THanks for the responce. TO point 1) could internal diverters/bafels not be used to help get even air distribution across the whole core?

 

I like it all together but I was supposed on the dyno runs that the temp was not closer on even the first run. 20 deg C on the IAT even for the 1st run seems pretty huge. So this doesn't necessarily show the heat dissipation effect of the large thin IC but rather how it can get the IAT down in general right? I guess I just expected them to start off closer that's all.

 

Baffles work well to do what you describe, when given enough "room to operate". With a wider core, the ends become pinched to the extent that baffles are of no use to direct flow to the upper areas. Here is an example of an intercooler where baffling works wonders:

http://www.awe-tuning.com/products/a...we-b7fmic.html

If you notice, there is still 25-35mm of endtank width at the top of the core in order to maximize flow to that area. Baffling helps in this design to direct air from the charge side upwards. Our pipes are shaped/directed to do that without the aid of baffling, and the endtanks designed to promote flow. Once the core is widened, this is no longer possible.

 

Excellent point. This test baffled us initially as well, but could be repeated every single time. We let the car idle up until operating temperature before the start of each run(approximately 10-15 minutes). No matter what we did, the IATs started higher with the stock IC in place. Our experience tells us that the larger core volume absorbs more heat which leads to lower IATs at idle. If you let the car idle for 25-30 minutes, our guess is that the IATs may start at the same place, but we wonder if anyone would let their car idle that long in the "real world".

 

Ok cool. I was just curious you know it wasn't like 5 degrees it was substantial even on the first run before any sort of heat soak. Very impressive.

 

We appreciate the positive feedback!