Oil/Water Heat Exchanger, Square Peg / Round Hole

Discussion in 'Mazdaspeed 3 General Discussion' started by jsmith, Jan 6, 2018.

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  1. jsmith

    jsmith Gold Member

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    So I scored a sweet deal on this laminova heat exchanger, but finding a home in my engine bay is proving problematic.

    IMG_20180106_161459.jpg

    I think the only possible way for this to fit on the passenger side is to relocate the OCC and mount the HX in-line with where the top port of the OCC was.

    IMG_20180106_155406.jpg

    Routing the water line outside the frame appears easy, getting it back into the bay not so much. Finding room for the two 10 AN lines to the sandwich plate should be possible as well.

    IMG_20180106_160934.jpg

    IMG_20180106_154517.jpg

    Does anyone have constructive suggestions for mounting and or routing that deviate from the plan above?
     
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  2. jsmith

    jsmith Gold Member

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    Parts ordered. ~5 foot of extra plumbing in the water loop.
     
  3. jsmith

    jsmith Gold Member

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    Progress update. Moved the JBR CC and mounted the kozmic CC. Ghetto mocked up the layout of the hose, HX, and its orientation.

    Still need to raise the Y joint to give whatever hose goes there room to bend.

    Kozmic CC and HPT meth tank do not fit without some lovin.
    IMG_20180112_151317.jpg

    The fog light has to come out for this to fit.
    IMG_20180113_135316.jpg

    Old photo of how the JBR OCC will be mounted. Its going to have its back up against the FMM with the offset provided by longer bolts and spacers in the frame rail mounts.
    IMG_20170228_163329.jpg


    Mockup before bracketing. HX is going to be attached to the pump under the washer res. Hose is going to be held in place via the orange clamp to the radiator support.

    IMG_20180113_132314.jpg

    Y pipe that needs to be relocated.

    IMG_20180113_132351.jpg

    The bend coming out of the radiator doesn't look too bad.
    IMG_20180113_132500.jpg

    Oil lines I think will head toward the front of the car before diving down and running underneath the radiator out hose to the oil filter.

    Comments?
     
    Last edited: Jan 13, 2018
  4. Mauro_Penguin

    Mauro_Penguin Punk in Drublic Silver Member

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    Your engine bay looks crowded as hell, but good luck with the project!
     
    Mauro_Penguin, via a mobile device, Jan 13, 2018
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  5. jsmith

    jsmith Gold Member

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    Some progress shots. The support brackets need to be remade about 1.5 inches higher to avoid hitting the inter cooler piping and to position the HX at the proper height. Routing has one more major issue that I see.

    Routing problem. Without a helping hand its possible for it to rub the inter cooler pipe. Best shot I have here is two clamps bolted together and bent appropriately. Not pretty, but effective perhaps.
    IMG_20180121_143523.jpg

    New bracket and clamp to help routing. Either the clamp is going to be swapped out for a smaller one, or more padding added to dampen motion.
    IMG_20180121_143217.jpg

    You can see the brackets are ~1.5 inches too low here, as well as the inter cooler piping interference. Note the 3rd routing clamp.
    IMG_20180121_143528.jpg

    Will be plenty of room front to back for padding between the brackets and the HX.
    IMG_20180120_175802.jpg

    Alignment for the outlet of the HX (inlet to the motor) is a bit higher, and closer together, than shown in this picture.
    IMG_20180120_175940.jpg
     

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  6. Mauro_Penguin

    Mauro_Penguin Punk in Drublic Silver Member

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    Cut up a spare couple and use it as a damping jacket between the intercooler piping and the HX.

    Nice little project so far. In for results.
     
    Mauro_Penguin, via a mobile device, Jan 22, 2018
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  7. jsmith

    jsmith Gold Member

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    The DS bracket is close enough to one of the washer reservoir support bolts that I may be able to tie into that in addition to the padding you suggest.

    Discovered last night that my minimum spacing between bends (dictated by my vise) is only a inch shorter than what is shown. Iffy territory for clearance on either bracket. :-/
     
  8. jsmith

    jsmith Gold Member

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    Ghetto bracket install is a go. Any interest from other people in mounting items using the PS pump bolts and bracket?

    IMG_20180219_193453.jpg

    I think to clear the bumper I will need to relocate this joint up and move the cooler over a 1/2" or so.

    IMG_20180218_194344.jpg
    Other side of that joint.

    IMG_20180219_193750.jpg

    My ugly as sin method of offsetting the IC and water lines.
    IMG_20180219_193542.jpg
    IMG_20180219_193614.jpg

    Catch can work on the driver side is almost done. A 90 degree and a 45 degree look like they will fit and clear the manifold and throttle body. Does the CS mani move the port on the bottom of the manifold?

    IMG_20180217_164322.jpg
    IMG_20180217_164340.jpg
    IMG_20180215_183834.jpg


    Even with the enforced bend, the IM line and the 90 deg fitting are very close.

    IMG_20180217_164353.jpg
     
  9. Mauro_Penguin

    Mauro_Penguin Punk in Drublic Silver Member

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    Would you save on hose clutter if you trade spots between the catch can and the cooler? From the pics it looks like a lot of criss cross.
     
    Mauro_Penguin, via a mobile device, Feb 20, 2018
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  10. jsmith

    jsmith Gold Member

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    That was my initial idea but wasn't comfortable with the idea of possibly boiling the coolant in the block after shutdown.
     
  11. jsmith

    jsmith Gold Member

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    Ayoustin was kind enough to help me make a better bracket than what I was using. Its attached to this post if anyone is foolhardy enough to want to try this at home.

    Car is running again, but probably wont have anything to add for a few weeks.

    IMG_20180317_174249.jpg

    IMG_20180317_174618.jpg

    edit: Thanks Raider for making the .stp upload possible.
     

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  12. Maisonvi

    Maisonvi Silver Member

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    FYI your stp file shows it in the flat config. I dont know if you would want to see the bent version for those of us who can actually open step files.
     
  13. AYOUSTIN

    AYOUSTIN Silver Member

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    Glad to see it fits up nicely. Looking forward to the finished product.

    I sent him the file for the flat version as I'd figured if anyone else was going to make this bracket they'd cut it out with a plasma or laser like I did and then bend it. I just set the machine to etch the center of the bend radius into the metal so I knew where to bend. If anyone wants the bent file I can post that up as well.
     
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