DIY Network

CO2 Intercooler-Sprayer: Interior Switches and System Check From "Tricked Out" episode DTRK-207

	The sprayer and solenoid installed on the intercooler.
	Installing the solenoid controller on the nitercooler sprayer.

In this project, host Andrew Totolos installs a carbon-dioxide intercooler sprayer on a Dodge SRT-4. The sprayer has now been attached to the intercooler. In this final phase, the project nears completion as Andrew and guest expert Dave Markley install the last two control switches and test the system.

Materials used in this episode:

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.), tools and materials used in this episode include:

Intercooler kit, including brackets, storage bottle and tubing
Installation kit
Sprayer
Mini fuse-tap
14-gauge wire
Electrician's grabber tool
T-25 torx-bit screwdriver
Drill and drill bits
Painter's tape and marker
Utility knife
1/4-inch bolts with nuts and washers
Thread-sealant tape
Safety glasses
Alcohol and towels
Metal ties
Metal snips
Eyelet connectors
Vehicle lift or jack stands
Vise

DIY Difficulty Rating for This Project: We gave this a difficulty rating of 4 on a 5-point intermediate-level scale.

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The CO2 intercooler-sprayer delivers colder, denser air to the combustion chambers for around a 7-percent jump in horsepower.

Cut To the Chase: How Many Horses?

So what is the result of adding a CO2 intercooler sprayer to your car? According to Dave, adding a system like the one shown in this project can increase the horsepower of your vehicle by five to seven percent. However, it should be noted that this is a system that is based on cooling the air flowing into the engine, so outdoor temperatures will play a role. The effect of the boost will be more dramatic on warmer days, for example, than on winter days when the air is already cold. Though 7 percent may not sound like a lot, it can make a real difference in competitive situations. In our case, this translated to an increase of about 11 extra horsepower. If the entire system with all the options installed, the boost could be as much as 15 percent.

Figure A

Installing the Interior Switches

The only thing left to do in this project is install the two switches that will control the sprayer: a master arming switch and a prime/purge button for activating the system when the car is not at full throttle (figure A). These are installed in a convenient spot on the dash. Once everything is up and running, the full-throttle pedal switch (previously installed) will take care of the operating details.

• Clean the dash area where the switches will be installed with rubbing alcohol (figure B).

• Use painter's tape and a marker to mark the location of the switches, making sure to check behind the dash for clearance, and drill out the holes.

• Use a fuse tap to draw switched power from the fuse panel, and connect it to the 12-volt terminal on the arming switch.

• Run a ground lead from a solid ground point to the negative terminal on the switch (figure C).

  Figure B

  Figure C

  
  

  	Figure D
  	Figure E
  	Figure F
  	Figure G

• Run a short jumper wire from the accessory terminal on the arming switch, combine it with a lead routed to the accelerator switch, and attach it to the primer button.

• Finally, combine the solenoid lead with an extension that also runs to the accelerator switch, attach it to the remaining primer terminal (figure D), and attach the other end of the accelerator leads to the micro-switch at the pedal (figure E).

• When all the wiring is done, push the switches through the holes from the back, and screw on the bezels to hold them in place.

A quick check of the system with the CO2 supply opened up about 1 turn, the arming switches on, accelerator pushed down results in the intercooler being bathed in very, very cold air (figure F).

Here are steps for using the system in a race application:

• When you get to the staging lane, open the trunk and open the CO2 valve about one turn.
  
• Back inside the car, press the arming switch.
  
• Press the purge (pre-cool) button.
  
• Let the system run for five to 10 seconds to cool everything down.
  
• Fasten your seatbelt, press the accelerator and hold on.

The Bottom Line:

$250 Intercooler kit
$190 Sprayer
$4 Mini fuse-tap
$3 Thread-sealant tape
$25 CO2 tank-fill

Total = $472

RESOURCES :

Sport Compact Bolt-On Performance Guide: Import Cars (Sport Compact Bolt-On Performance Guides)
Author: Joe Pettitt
Order this book from Amazon.com.
Voyageur Press (October 2000)
ISBN: 1884089526

GUESTS :

Dave Markley
Design Engineering, Inc.
Avon Lake, OH
Phone: 800-264-9472
www.designengineering.com