Over the last several months we have developed a new concept in intercooling for BMW applications, and decided to apply it to our R56 MINI. It utilizes dual-thickness cores to maximize both frontal area as well as core thickness. The end tanks are cast, and as you can see in the design pics, encompass both cores. The idea is to be able to install the intercooler without cutting or other permanent modifications, and fully utilize the space at the front of the car. The test prototype is being assembled as we speak and we expect to see it here soon.

Here's a side shot:




And here's a 3/4 view from the rear:

 

What are the advantages of the thicker lower part? I don't have a clear idea of the R56 engine bay as I have an R50 but my guess is that it would go further toward the centre of the engine bay, wouldn't this push that section too near to the engine itself, thus in an hot area?

 

the oem intercooler on the turbo'ed r556 looks to be about the size of the 'thicker' part. My guess is the new thinner section will go in front of the radiator.

Like everyone else, I have an opinion.

 

It's no closer to the engine than stock.

 

Oh, ok then. thanks for the clarification

Yeah, I understood that from heyduard's post.

 

Looks like air flow inside could get turbulent.

 

Which would be good for the heat exchange, from what my studies tell me However, if I don't remember bad, it could also cause a raise in the inlet/outlet losses...

 

nice idea!

what are the advantages over going for a thinner coore thats taller??? im just wondering why no one else has tried this yet.

Cheers

Chris.

 

About time someone came up with this approach without any mods required to fit.

What about mounting points. Will this IC be secured at OEM points ?.

 

This style has been done already by RMS in Germany. However it doesn't use factory mounting parts and thus requires drilling to the front crash beam to secure the upper edge of IC.

 

It uses the factory mounting brackets with no drilling.

 

Any idea of price yet.

Any dyno figures !.

 

We're not at that stage yet, but will of course post numbers and prices closer to release.

 

Looks like a winner. Looking forward to seeing it in use.

 

looks like a good design. Granted i don't know squat about ic development... but i'm sure helix will do everything necessary to make a quality product.

 

You may have an efficiency issue here. The lower core closest to your outlets will have the greatest resistance to air flow through the core.

A medium thickness core would have a higher efficiency I believe.

 

I helped Eric design this intercooler, the entire core uses the same internal fin count so it will have the same resistance through the entire core. this design was done in order to maximize the available area in the front of the car, we streamlined every aspect of the cast endtanks to get air to flow as best we could. Once we recieve the final prototype we will run it through a battery of tests and dynos you guys will get plenty of data

 

I'm not sure where that speculation comes from. That has not been the case with the BMW intercoolers. Testing tells all.

 

Not trying to put the design down. Just something to keep in mind. The speculation comes from years of being an engineer. It is my job to optimize designs everyday.

 

We have the first prototype, which we'll install as soon as we get a minute to breathe. We are booked solid through the fourth week in January, so our testing might be a little slow, but we'll keep you posted. Here it is:

 

Nice! Quite interested to see how the testing goes.

 

+1

 

What he said. . . . .

 

I was wondering if you guys were going to make this for the R56 after seeing it for the 3 Series on your adjoining site.

 

The IC above is for the R56. Or did I just read your question incorrectly???