MikeChaotix.com - 3rd Place Winner of the 2006 "Most Useless Website" Award.


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Basic Idea


Living in the desert can mean trouble for a turbo car.  Turbo cars generate extra heat, and extra heat, combined with high temperatures can mean power loss and even strong detonation for your car.  As you probably know there are plenty of intercooler spray kits available out there for 100+ dollars.  But why spend that much when you can get the same results for less than 15 dollars?  First thing you must realize is that I own a WRX Wagon.  This installation costs you the use of your windshield wiper fluid pump.  Lucky for me, the Wagon has two pumps; One for the rear, and another for the front.  If you own a sedan, you only have one pump and will lose your front wiper fluid spray.  Still, the idea is very simple; we just disconnect the pump from the main line going to the rear of the car, and replace it with new line that runs to a number of spray nozzles.  To activate the spray you simply need to use your fluid button.  Sedan owners will have to pay a little more to fabricate another button to activate the pump.  I’m going to be attempting to wire that to save my rear wiper.

And the 15 dollars goes to….

Along with some irrigation tubing and 6 T fittings, I bought two types of nozzles, “Arizona Mist Nozzles” and “DiG Fogger Misters” designed for irrigation.  I had to experiment before I could determine the right nozzles.  First off, the Arizona nozzles made the best, finest mist.  In fact it was so fine that it evaporated to fast.  Also, had trouble with the pressure in the line, the nozzles would pop off from slowly building pressure.  Fogger Misters from DiG were nearer to perfect than most other nozzles we tried.  It made a good 360 degree mist that spread over more area than I needed.  We returned the un-needed nozzles and were refunded courtesy of Home Depot.

Disable Wiper

The problem behind this is; to activate the pump you use your fluid mist button, which unfortunately also activates your wipers.  To solve this, we simply just disable the rear wiper.  Remove the gray fabric-like material.  It is latched on by small plastic push-in clips.  It’s very easy to remove, once removed you’ll see the plug for the rear wiper.  I can only describe it as a light yellow plug that requires a pair of pliers to disconnect.  Once un-plugged, let it hang there and reinstall the cheap upholstery cover.  Now you can use the pump without having a wiper wiping your window.  As I mentioned earlier, if you own a sedan, that’s another story.  You’ll want to wait.  I’m in the process of to splicing the wires and attempting to make an alternate power source and button to activate the pump.  I’ll be posting a write up on that in the near future too.

 

Assemble Lines, & Connect Pump

Once you unbolt the reservoir you’ll see two pumps; one for the front fluid misters, and the rear fluid misters.  The black one is for the front, and the white one is for the rear.  Just by activating each one, you’ll notice the white pump seems more powerful.  It’s more powerful because it needs to pressurize the longer line going to the rear of the car.  This makes it more ideal to use in this situation.  Cap off the line going to the rear, and let that hang there, its short and won’t go anywhere so don’t worry.  Wash out your reservoir of any remaining washer fluid.  Now connect the line, and reinstall the reservoir.  ‘Very simple no?’

 

Scoop/IC Nozzle fitting

I attempted a number of designs around/surrounding my Intercooler, I even considered drilling a hole on the intercooler flaps on the sides to hold up a metal bar to aim the misters perfectly.  However, considering the work, and mess I came up with a much easier way to lever and aim the misters.  The first setup (figure A) was used with a coat hanger and zip ties.  This worked well and the intercooler was no longer hand burning hot after driving around.  However, certain parts of the intercooler were still hot, and the nozzles were to close to the intercooler.  Then I came up with the 2nd setup (figure B) which worked much better.  It required me to punch extremely tiny holes in the rubber shrouding, and 5 zip ties to secure the nozzles and T fittings.  The intercool was getting spray to all areas; in fact I think it can be considered overkill.  (The STI has only one mister) 


Figure A

Figure B

Conclusion

The ultimate test happened when I drove to the beach with my friends.  A 3 n’ half hour trip, an extra 45 minutes from heavy stop and go traffic, which caused some heat soaking.  After the trip, the intercooler was warm to the hand.  Keep in mind, if the intercooler feels cool to the hand, the intercooler spray wouldn’t be very effective at all.  Considering desert hot weather in my area, a “warm” touch is a big improvement over the “Oh Sh*t! I burnt my pinky” touch.