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Stock intercooler vs VMP intercooler

2632 Views 34 Replies 6 Participants Last post by  eschaider
Hi there, just wondering is the stock intercooler really that much of a restriction as far as getting air through it? Is the upgrade worth it? I don't see a lot of data on it or threads out there about a before and after.

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I want to say MalcolmV8 and James at Cobra Engineering both compared the two ICs. I no longer have the hard numbers but, I seem to recall the VMP unit was a definite step in the right direction. Check out both their YouTube channels and I think you'll find additional information, Justin.
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Right on thank you Ed, I'll do that and report back. I do remember Malcolm doing something on that now that you mention it.
Justin, also, check out the LFP replacement intercooler. It is about half the price of the VMP unit, but I think is close to the VMP unit in heat dissipation, and it is 50¢ on the dollar.
Justin, also, check out the LFP replacement intercooler. It is about half the price of the VMP unit, but I think is close to the VMP unit in heat dissipation, and it is 50¢ on the dollar.
Oh yeah I see that very nice. Hey while I got you, what's your opinion on this. I'm on a 3.4 Whipple at 28 pounds, my best is a 9.81 @ 140. Do you think a ported 2.65 VMP at 28#'s would produce MORE power, more importantly better times at the track? I'm kind of thinking of changing things up and that's the reason for the intercooler thread. Because if I pull the bower I might as well upgrade the intercooler. I like the VMP because of their removable inlet.

Sorry off topic but that's the reason behind the thread.
VMP is a good blower, so is the 3.4L Whipple. Whipple rotor technology has developed significantly since the 3.4L blower. They have 3.0L blowers that run 8.40s at 160+ in 03/04 Cobra's today. Click here => AJ's Ride
I know this is cross posting a bit, but based on your IAT2's alone, it's not a restriction at where you were/are at (but we don't know the exact boost level you were running, and either way, you have something going on that is drastically effecting the power). The stock intercooler is quite efficient. With that said, every little bit helps and the VMP is an extremely nice piece. If you're replacing the intercooler, don't bother with the LFP, just go directly to the VMP with the cobra engineering manifold.

With the Whipple 3.0, the plugs are a bit easier to get to, no need to remove the inlet. I know it sucks on the 3.4. With the 3.0, easiest to remove the throttle body, then you can get to everything. If you remove the IAC on the elbow, even easier. Either way, not an issue.
Justin, I didn't see your IAT2 temps. What are you seeing for IAT2 temps? Steve, where did you find the temps?

Back to Justin, what pulleys are you running on the 3.4L Whipple? If you can give us that information, the fuel system calculator can provide a pretty good approximation of the boost level the engine is seeing.

Steve's comments about the intercooler are correct. While a few notches down from optimum, the OEM intercooler is nonetheless pretty good until it starts to get plugged up. It is true that the fluid path in the VMP is much less restricted than the OEM piece, and even the LFP unit offers better fluid flow. The pregnant question is, is an $1800 IC package ($1,400 intercooler with a $400 coolant adapter) $1,000 better than an $800 LFP alternative?

As the OEM intercoolers age and the users do not maintain them by periodically cleaning and back-flushing them, their thermal performance deteriorates. Once the process becomes sufficiently advanced, the best fix available becomes a replacement. At the replacement threshold, you need to ask yourself the important question do I get $1,000 more performance out of the $1,800 package than I get out of the $800 package? If the car is a dedicated race car, the answer could be a yes — because it is about winning. However, if the car is a street-driven vehicle that is occasionally raced, the answer is — not likely!

AJ's car has never had anything but the OEM intercooler in it. With a T-400 auto and a 4000 or so stall converter, he has run into the low 8.40s and well over 160 mph. I believe he has low 8-second, possibly high 7-second potential at mid to high 160 mph trap speeds. I would save that extra $1,000 (and maybe $1,800) you are thinking about spending on a replacement IC and put it toward a 3.0L Whipple — it would be money much better spent. Take your existing IC to a radiator shop and have them back flush it, put it back on and use a noncorrosive IC fluid. Sell your 3.4L for whatever market is, and you will have a less expensive, more satisfying upgrade than the IC upgrade path you are currently contemplating.
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He sent me a log, downstream temps through the traps are low 120's starting at 90, which is really good for what he has, and also partially why I don't think his car is actually seeing 28#'s (belt slip?). Unfortunately, MAP was not being logged.

ETA: In fairness, it's not a full pass. Extrapolating (guessing), he lets off 7.5s in to the run, and the iat2's are 122 (starts at 90). Comparing it to my logs with the 3.4 whipple/stock longblock on a 6.0 1/8 and 9.4 1/4 pass, at 27 pounds, and the stock intercooler system, I start at 84*, see 120* 7.5 in to the run, and 125* through the traps. Or the stock intercooler system works fine either way, just not ideal with a 40* rise. As a comparison, with the 3.0 whipple (with VMP and cobra engineering adaptor), on my 8.6 pass and 28#'s, I start at 104* and pass through the traps at 129* (126* 7.5 seconds in to the run), or a 25* rise with more boost. It's the same icing for both, 1 bag precool, 2 bags for the pass.

On the intercooler, the budget way of squeaking out the most performance is modifying the intercooler manifold adapter while keeping the stock intercooler, arguably the most cost effective path. But you do have a good point of not knowing the condition of the stock intercooler.

For his goals, the 3.4 is capable of the number he wants with what he has.

Ed, my car has been 8.6's at 160mph second pass with the 3.0/th400, losing second gear, at 28#'s of boost and a couple hundred heavier than AJ (crossed the scales at 3642 pounds, I'm still a full stock interior car ). And 14.2* timing. I'll be back at the track on Friday finally to see if I can play with the tune. The 3.0 is a great blower, and I have no doubt that a bunch of us will be deep in the 8's early spring, if not within the next couple weeks. First pass off the trailer I made an 1/8 pass and went [email protected], second pass lost 2nd gear and let out before getting back on it but went [email protected] ([email protected] in the 1/8).
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That all makes sense now, Steve. At first, I thought I missed something in one of the posts, and then I was beginning to think you might be clairvoyant! :giggle:

Your experience with IAT2 temps with a 3.0L Whipple is spot on. The rotor profile used in the 3.0L blower is a more efficient profile with less leakage between the rotors and also the case, which produces a cooler, denser charge at any given overdrive. Your performance numbers are also spot on with what I would expect from the engine in a Terminator chassis.

The 3.4L rotor profile is two, perhaps three generations earlier than the 3.0L compressors. The difference in rotor profiles accounts for the higher discharge temps on the 3.4L blower compared to a 3.0lL rotor at the same boost level. Your observations about the launch and quarter mile temps indicate how much more efficient the 3.0L rotor profile is.

Although the final decision always rests with the car owner, I would seriously consider keeping the OEM intercooler and, instead of upgrading to a TVS blower and intercooler, putting a 3.0L Whipple on the engine. A new G3 TVS for a Terminator is $4,500. The excellent VMP intercooler with the Cobra Engineering coolant adapter is another $1,800 for a total major parts cost of $6,300.

By comparison, a 3.0L Whipple for a Terminator is also $6,300 and provides a much higher ultimate performance level for the car. I am not sure of the current retail value of a used 3.4L compressor, but it would impact either purchase decision similarly, reducing the out-of-pocket upgrade expense. Therefore, my admittedly biased opinion is the 3.0L Whipple would produce a better performance improvement for the same dollar spent.

Again, however, the final arbiter is the man writing the check and whatever he chooses is, by definition, best for his ride.
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Thank you for the insight Ed and Steve. My upper pulley is a Griptec 3.5" with a 6# (9.1" lower). I am leaning towards pulling the trigger on a 3.0L Whipple. I swear my 3.4 has got to be one of the first gens and changing spark plugs is a pain. So to hear Steve say the 3.0 Whipple is easier changing the plugs makes it way more appealing. Plus the new rotor pack like you mentioned Ed. What you said makes a lot of sense too Ed about breaking down the cost, would you guys get the race port on the 3.0 Whipple?
That all makes sense now, Steve. At first, I thought I missed something in one of the posts, and then I was beginning to think you might be clairvoyant! :giggle:

Your experience with IAT2 temps with a 3.0L Whipple is spot on. The rotor profile used in the 3.0L blower is a more efficient profile with less leakage between the rotors and also the case, which produces a cooler, denser charge at any given overdrive. Your performance numbers are also spot on with what I would expect from the engine in a Terminator chassis.

The 3.4L rotor profile is two, perhaps three generations earlier than the 3.0L compressors. The difference in rotor profiles accounts for the higher discharge temps on the 3.4L blower compared to a 3.0lL rotor at the same boost level. Your observations about the launch and quarter mile temps indicate how much more efficient the 3.0L rotor profile is.

Although the final decision always rests with the car owner, I would seriously consider keeping the OEM intercooler and, instead of upgrading to a TVS blower and intercooler, putting a 3.0L Whipple on the engine. A new G3 TVS for a Terminator is $4,500. The excellent VMP intercooler with the Cobra Engineering coolant adapter is another $1,800 for a total major parts cost of $6,300.

By comparison, a 3.0L Whipple for a Terminator is also $6,300 and provides a much higher ultimate performance level for the car. I am not sure of the current retail value of a used 3.4L compressor, but it would impact either purchase decision similarly, reducing the out-of-pocket upgrade expense. Therefore, my admittedly biased opinion is the 3.0L Whipple would produce a better performance improvement for the same dollar spent.

Again, however, the final arbiter is the man writing the check and whatever he chooses is, by definition, best for his ride.
He sent me a log, downstream temps through the traps are low 120's starting at 90, which is really good for what he has, and also partially why I don't think his car is actually seeing 28#'s (belt slip?). Unfortunately, MAP was not being logged.

ETA: In fairness, it's not a full pass. Extrapolating (guessing), he lets off 7.5s in to the run, and the iat2's are 122 (starts at 90). Comparing it to my logs with the 3.4 whipple/stock longblock on a 6.0 1/8 and 9.4 1/4 pass, at 27 pounds, and the stock intercooler system, I start at 84*, see 120* 7.5 in to the run, and 125* through the traps. Or the stock intercooler system works fine either way, just not ideal with a 40* rise. As a comparison, with the 3.0 whipple (with VMP and cobra engineering adaptor), on my 8.6 pass and 28#'s, I start at 104* and pass through the traps at 129* (126* 7.5 seconds in to the run), or a 25* rise with more boost. It's the same icing for both, 1 bag precool, 2 bags for the pass.

On the intercooler, the budget way of squeaking out the most performance is modifying the intercooler manifold adapter while keeping the stock intercooler, arguably the most cost effective path. But you do have a good point of not knowing the condition of the stock intercooler.

For his goals, the 3.4 is capable of the number he wants with what he has.

Ed, my car has been 8.6's at 160mph second pass with the 3.0/th400, losing second gear, at 28#'s of boost and a couple hundred heavier than AJ (crossed the scales at 3642 pounds, I'm still a full stock interior car ). And 14.2* timing. I'll be back at the track on Friday finally to see if I can play with the tune. The 3.0 is a great blower, and I have no doubt that a bunch of us will be deep in the 8's early spring, if not within the next couple weeks. First pass off the trailer I made an 1/8 pass and went [email protected], second pass lost 2nd gear and let out before getting back on it but went [email protected] ([email protected] in the 1/8).
... would you guys get the race port on the 3.0 Whipple?
Absolutely Justin! The race port does not adversely affect street performance. It just allows the blower to breathe easier (pull in closer to its actual 3.0L displacement) with each rotation of the rotor pack. Think of it as the difference between having your throttle wide open vs three-quarters open. It is really that simple. Notwithstanding its naming convention, it is the absolute right thing to do.
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I have the whipple race port, other than cost, there are no downsides. The cost is not insignificant though, just as the intercooler discussion went. Most all of us running the quicker numbers have ported blowers, some race ported, others by outside companies. What seems most prevailing with the port is that it allows all the boost far past the RPM's that any of us run them, it never runs out of steam. It's supposed to run cooler as well, though I think it's an insignificant and irrelevant amount. For your current goals (and far exceeding them), you really don't need the race port. The 3.0 without will achieve them, but so will that 3.4 that you have.

On the 3.4 crusher, for the number 3 and 4 cylinder, I used a combination of 1/4" swivels, extensions and adapters, as well as some 3/8. Once you have a dedicated setup taped together just for those cylinders, it goes quick. On the 3.0, you need one 3/8 swivel, 6" extension and that's it for the number 4.
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Not trying to hijack the thread but I feel this is very much inline with the discussion.
This is all great information to hear. I have already bought the 3.0 Whipple with the 150 mm throttle body. However I didn’t get the race port (simple regret to fix). I still have the stock intercooler at this time so my question is which of the 2 at this point would be the better bang for the buck purchase? Send the blower off for a race port or one of the 2 mentioned intercooler upgrades?
In addition which would be the best route for the race port? Send it back to Lethal/Whipple for the race port or a third party vendor for porting?
Lastly regarding the port which other vendor has shown to be responsible for an as good as or better port job versus Letha/Whipple (if that exists)?

In the end I’ll probably do both port and IC upgrade. I’ve spent so much time and money to do this the absolute best way possible with my Cobra. I haven’t left any stones unturned so far and I want to call this car DONE when I finish it with no regrets or desire to tear into it again for any reason.
Quick rundown is 10.5:1 Gibtech/Aluminator/Molnar PA rods-with all ARP studs and all the upgrades, Brand new FRPP cnc ported heads, custom cams, MS3-Pro with E85 and full flex fuel and all of its bells and whistles, return fuel system and Lentech 4r70w with a PI 3800 converter.
The only thing I may change after the fact would be to switch the transmission out for a built 4l80e or a built 6r80 with a 4000 stall +/-
Sorry for the long read and I hope I didn’t step on the toes of the OP’s original thread with my questions!

Thank you,
Ken
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Not trying to hijack the thread but I feel this is very much inline with the discussion.
This is all great information to hear. I have already bought the 3.0 Whipple with the 150 mm throttle body. However I didn’t get the race port (simple regret to fix). I still have the stock intercooler at this time so my question is which of the 2 at this point would be the better bang for the buck purchase? Send the blower off for a race port or one of the 2 mentioned intercooler upgrades?
I am not certain anyone has done the comparison you are looking for, Ken. Both approaches will increase the air mass and density entering the engine. Speaking entirely from an intuitive and not a quantitative perspective the porting of the blower inlet that Whipple does is effectively the equivalent of running a larger throttle if the compressor is throttle area/flow limited. The porting will increase flow. The porting process essentially removes blower casting material from the air inlet ports on the entry side of the Gen 3 case providing less restriction to incoming airflow — essentially the same as replacing a small throttle body with a larger throttle body. That is the good news.

The increased flow and air mass when pumped into the 4.6L engine displacement will increase both charge density and charge temperature. As we all know increased charge temps demand reducing the timing to avoid detonation. The single most powerful metric to control engine torque is timing. If the increased air temp causes you to pull timing, then the porting initiative was at best a wash and potentially a step backward.

If I couldn't do both simultaneously I would do the intercooler upgrade first. Under no circumstances will it hurt power and it is a certainty that cooler denser charges will provide a power increase. After you have the new intercooler in and plumbing sorted out, then you can move on to the ported blower at a more leisurely financial pace — if there is such a thing


In addition which would be the best route for the race port? Send it back to Lethal/Whipple for the race port or a third party vendor for porting?
My suggestion would be direct to Whipple. Whipple's new generation of rotor profiles came out of research that Lysholm did in years past to optimize rotor profiles. To my knowledge, the research never translated into a commercial Lysholm rotor or blower with the rotors installed. While others can probably guess pretty close what the blower wants and the case can tolerate, in terms of porting, Whipple knows! I would be reluctant to risk the blower performance and the blower's mechanical service record you get with a Whipple port vs an aftermarket port.


Lastly regarding the port which other vendor has shown to be responsible for an as good as or better port job versus Letha/Whipple (if that exists)?
To my knowledge, no one has provided a port that improves on the Whipple ported Gen 3 performance or longevity. Both attributes are important to evaluate. Some aftermarket service providers may come up with their own ideas of how the blower should be ported but at best those attempts will primarily be SWAGs (Scientific Wild Ass Guesses). The technique involves modifying someone's blower to see if the car performs better. Whipple uses Computational Flow Dynamics in their compressor designs. Most aftermarket efforts can not afford that type of design expertise or expense.


In the end I’ll probably do both port and IC upgrade. I’ve spent so much time and money to do this the absolute best way possible with my Cobra. I haven’t left any stones unturned so far and I want to call this car DONE when I finish it with no regrets or desire to tear into it again for any reason.
I think your instincts are spot on.


Quick rundown is 10.5:1 Gibtech/Aluminator/Molnar PA rods-with all ARP studs and all the upgrades, Brand new FRPP cnc ported heads, custom cams, MS3-Pro with E85 and full flex fuel and all of its bells and whistles, return fuel system and Lentech 4r70w with a PI 3800 converter.
The only thing I may change after the fact would be to switch the transmission out for a built 4l80e or a built 6r80 with a 4000 stall +/-
Sorry for the long read and I hope I didn’t step on the toes of the OP’s original thread with my questions!

Thank you,
Ken
Very nice component selections and finished engine spec, Ken
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Thank you Ed. I’ll do the intercooler upgrade first (which is what my gut was telling me). I’ll still end up porting the blower but I can move it down the priority list somewhere right before bolting the blower to the engine.

As far as my component and engine spec choices. I’ve listened to you and the rest of the guys here who have posted their builds and parts that have been proven to hold up and work well.

Thanks,
Ken
It's kind of a catch 22. I don't have ported heads, but similar compression, ported 3.0, VMP, and auto (TH400 though) on MS3/pump e85. If you don't plan on running higher boost, there is no real need for the intercooler. If you don't plan on running higher boost, there is no real need for the ported blower. If you plan on running higher boost, the efficiency of both are much improved when both are done. You'll pick up a couple more pounds of boost with the ported blower, and run a bit cooler pound for pound, but if you run it up higher, you will eventually start wanting the additional air flow and cooling capacity of the intercooler. Also remember to budget in for the Cobra Engineering water manifold when you do the VMP, otherwise, any improvement in water flow is completely offset.

Get the Whipple race port or nothing. They CNC port the inlet as stated, but they also open up the case as well as the discharge area.

In your case, I would wait to pull the blower until you are ready to do both, or at least wait until you have some data. The stock intercooler *with Cobra Eng. and J2 water manifolds and the UNported G5 3.0 have both laid down very impressive power, 1100rwhp and low 160 traps. You'll need to define your goals with the car and take it from there.
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Engine hasn’t been completed as of yet, so this is a brand new build in progress. Goals are mid to upper 8’s set on kill on E98 with 28+ pounds of boost for the track. Street will be toned down to use pump E85 and whatever boost the car seems to like in conjunction with the traction control and knock control. I’m guessing somewhere in the low 20’s more than likely.
I won’t have any previous data on my car to rely on, just that of those who went before me. My previous engine setups were stock motors with the exception of a KB 2.2 briefly and a ported and pulley’d Eaton with the 4r70 and SRA swap. Car has seen zero run time since 2006 except for a 2 week stint in mid 2009 totaling about 250 miles before loosing a head gasket. It’s been sitting in the garage ever since while I slowly collected the part’s I wanted to build it into a “finished once and for all” version to enjoy and raise eyebrows at the track.
You’re really selling yourself short on goals. My numbers are on the first trip out at 28 pounds low timing and less than optimal a/f, leaving in 2nd with a converter that slipped 17%. On pump e85. I’m a full weight stock interior street car as well.

Since it’s not together yet, I’d highly recommend just doing both the VMP/cobra engineering and the race ported whipple. With your higher compression and ported heads, low mid 8’s should be easy at 28#’s. Once you get it together, let me know what kind of info you need to get you there.
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Steve's points are well made and come from personal experience so they have significant value, Ken. Here are a couple of other data points that might also be helpful;

These engines make an extraordinary amount of power, especially for their size, when you clean up the intake (TB, inlet and blower), use good but not great intercooling, and just let the engine do its thing. An example of this is AJ's (Mofasta) car. While he doesn't have a back seat, he still weigns ~3500/3600 lbs. His car with an unported 3.0L Whipple and a stock intercooler runs 8.40's at 160+. AJ uses an ice tank in the trunk for chilling the intercooler.

I suspect you will easily hit and probably eclipse the performance marks you have for your car. My only design-related comment would be with respect to the fuel system. When you go to 100% E-85 the engine's appetite for fuel will grow surprisingly big. The two tender spots will be injector size and fuel pump size / quantity,

Initially, AJ ran two MagnaFlow 43XX pumps (can't remember the numbers) that were the largest electric gear pumps Magnaflow offered. If I remember correctly they were rated around 2000HP or so each. His engine needed two of them and he did not make 4000 hp he was probably down around 1100 maybe 1200. AJ was also different from you in that he ran methanol rather than ethanol or E85. Both Ethanol and Methanol have very large fuel volumes required compared to gas so you want to be cognizant of that in terms of both your injector sizing and also your fuel pump sizing / selection.

To accommodate the volume of fuel he was consuming AJ required two 2200 cc injectors per port. You will have a lesser appetite for fuel, because of the use of ethanol instead of methanol but you could still be close to or just over a single 2200 cc injector. Use the fuel system calculator to noodle that out. If that is where you do end up dual injectors make for a better / easier idle and better throttle response. Dual injectors also make for an expensive manifold modification.

In the oh BTW department the Magnafuel pumps worked so hard the electric motors failed and had to be rebuilt. After, I think, the second failure AJ converted to a cable driven mechanical fuel pump that he located in the back by the tank and has had no fuel pump issues since.

If I remember correctly his manifold boost was 24 or 26 psi when the car was running low 8.40s at 160+. AJ's cage was not certified for quicker than 8.40s so he would pedal the car in high gear to avoid running quicker. I believe with or without the ported blower and the better IC you will have a tiger by the tail. The only other mechanical difference between you and AJ is compression. He runs more than you do but his car is not street driven, very often (he has been known to cheat from time to time and drive it on the street).
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