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Data Logging the Intake System
I have reported some temperatures in threads on NAM, and will
have to get them down here at some point.
Lately I have been logging data on my airbox temps to see how
the FAD and insulation is working, as well as IATs from the SGII. Below
are some time-based graphs of airbox and IATs relative to ambient temps.
The first is a evening commute (5pm) and the second is a morning commute (8am).
These highlight a few points I've made on NAM:
(i) IATs are highly variable especially when commuting.
Asking an IC and other intake air cooling system to deal with stops, starts,
idles, short fast low gear accelerations, and few extended cruising
opportunities is a tall order. Generally an approach (IAT - ambient) of
under 20F is good, under 10F is excellent. You need help (like water-meth
injection) to get it negative!
(ii) Airbox temperatures are very close to ambient with the FAD and lots
of insulation including a box lid. This is an Alta system with 3 air
sources: cowl, FAD and front air duct above the radiator shrowd. It
rejects engine bay heat well, it cools quickly and is capable of sub-ambient
temps.
(iii) IAT approaches are pretty low (sub 20F) and controllable when
freeway cruising, but are unmanageable in normal to heavy traffic. But
then again, do you really want ultimate response and performance when surrounded
by that many idiots sharing, or not, the roads while you commute?
Commuting is hell, and these graphs prove it.
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The equipment
Part of learning about Air Intakes in the MINI is taking
measurements, since I believe that more information is helpful.
Measurements are not the only things to consider, but they are more accurate
than "feelings" especially those generated by a butt dyno! Intercoolers
basically have 2 parameters of concern: temperature drop measured by thermal
efficiency (TE) and pressure drop, measured as a delta of boost pressure across
the IC. I am currently measuring thermal efficiency throughout the entire
Intake system. I can measure the temperatures at the following locations:
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 temperature gauge)
4. post-IC, at the exit plenum of the IC (measured by a probe connected to
a 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.)
Below is a picture of the VR temperature probe inside the
outlet of the DFIC.

Here's what the gauges in the car look like:
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