Evolution Racewerks Competition Series Front Mount Intercooler (335i/435i)
Evolution Racewerks Competition Series Front Mount Intercooler (335i/435i)
The wait is over. With over a year of development and testing on a stable of test cars in different racing conditions, we're proud to introduce the new Evolution Racewerks Competition Series Front Mount Intercooler (FMIC), the ultimate intercooler solution for your 335i and 435i!
Ease of Installation: (1 Easy, 5 Hard) 1
- Designed specifically to fit (and look good) on the 335i and 435i.
- Large 20"x11"x3" (26"x11"x3" with end tanks) High Density Bar & Plate Construction Intercooler Core
- Cast end tanks for improved durability and internal flow characteristics.
- Brush finish standard
- Optional Polished finish available.
- Optional Type III Hard Black Anodizing (for stealth) finish on the intercooler, end tanks and all piping. Hard anodizing helps improve durability of intercooler fins against damage from road debris (rocks).
- Features the factory style connectors. Fully compatible with factory piping or aftermarket piping utilizing factory style connectors. Compatible with our charge pipe upgrade kit.
- Maintains ALL factory components. No modifications required. 100% bolt on.
- Includes all hardware needed to install.
- Developed and tested for over a year under the harsh conditions of racing.
- Limited Lifetime Warranty.
The heart of the ER Competition FMIC is the massive 20"x11"x3" (26"x11"x3" with end tanks) featuring our famous high density bar and plate intercooler core. It features 660 cubic inches of very efficient high density bar& plate core (35% larger) versus the factory 425 cubic inches of less efficient tube & fin core. Through extensive testing of different types of intercooler cores (tube & fin, bar & plate) we developed our own high density bar and plate core. What's different about our bar and plate core you ask? Fin density. Why is this important? The fins are the main heat transfer surface. More fin density = more actual surface area. What does this mean in the real world? Most quality intercooler cores utilize around 12-14 fins per square inch. Cheap quality oversea cores utilize around 8-10 fins per square inch (some even lower) which explains why they perform so poorly even though a large core is utilized. Our Evolution Racewerks cores are 18-20 fins per square inch. What this means is that compared to a cheap overseas core, we can get the same efficiency in roughly half the core size. Now imagine if they're the same size!
Independent testing (by customers and shops) throughout the years have shown that time and time again, our intercooler cores have outperformed our competitors. We've even had competing companies utilize our intercoolers for competition instead of their own! The independent test data below shows that our FMIC is so efficient in cooling that it has cooled intake air temperatures (IAT) to almost ambient (outside) temperatures. We also did extensive testing on the proper size to use to effectively cool the hot charged air as well as fight off heatsoak (when the intercooler cannot transfer heat away faster that the heating building up from the hot intake air). Heatsoaking is not an issue at all as shown by the consistency of the IAT staying in the same temperature range throughout the WHOLE RPM powerband. Also, our FMIC recovers so quickly after a full throttle pull that once you shift, it recovers completely. This is why pull after pull, our FMIC does not heatsoak. Beat on it all day long and the IATs will consistently stay the same. Our Competition FMIC is just what it is called, designed for competition. Other brand intercoolers may be adequate for short period pulls like the 1/4 mile (with hours between runs to cool down). Our intercoolers are designed to withstand the rigors of harsh racing conditions like road racing where you are at full throttle for long periods of time, sometimes behind other cars blocking direct airflow needed to cool down your intercooler. With countless test and competition laps around our local racetracks in 100+ degree weather, heatsoak is not a problem on our 135i Time Attack race car. With it's size and ability to support over 600hp, it is most likely the "last intercooler you will ever buy".
One of the most overlooked aspect of intercooler design is the intercooler end tank and piping. Having shorter and less bends on the intercooler piping will promote better internal flow. This helps in reducing turbo lag, increase throttle response and faster boost spool ups. An intercooler end tank must be designed to channel and distribute aircoming in from the inlet efficiently throughout the intercooler core. Our end tanks are designed to promote smooth internal air flow. The cast end tanks allow us to have nice smooth radius on the inner edges of the end tank, causing less turbulence.
One of the first things we noticed when we started development of our Competition Series FMIC for the F Series Chassis cars is that there is much more space behind the bumper cover compared to the older E Series Chassis cars. Without any major space restrictions, we chose to move the intercooler forward from the factory location. This allowed us to have an intercooler with more frontal surface area and more direct airflow without having to sacrifice internal airflow with an odd shaped end tank. Our test data on this design showed improvements in both IATs and ability to fight off heatsoak. Another added benefit of moving the intercooler forward is that now, intercooler sits more aggressively behind the center bumper cover.
Unlike turbo kits and other parts where the main power adder is constant, intercooler gains (or recovery) is based largely on how badly the current intercooler setup working and will vary from setup to setup. Dyno graphs do not properly show the performance of intercoolers, intake air temperatures do as that is the job of the intercooler. A car running factory boost pressures and our FMIC will see lower gains than another car running more boost (software upgrade) with the same FMIC. Even running upgraded downpipes and exhaust will affect overall gain (or recovery). However, it will still be a question people will ask and the simple answer is on average, you will see a 15 to 25 hp to the wheels gain based on your modifications. On high boost cars, we have seen 25+ hp gains.
The Competition Series FMIC comes standard with a brushed finish. We also offer and stock our intercooler applications with a polish finish or our Type III Hard Black Anodizing for the guys that want the stealthy look. With the Type III Hard Anodized FMIC, it is very hard to tell there is a FMIC on the car. Most of our customers with the Type III Hard Anodized FMIC comment that unless you know there is a FMIC on the car, nobody notices it. Another added benefit of the Type III Hard Anodizing is that it makes the intercooler fins harder and stronger, which makes it less prone to getting bent/damaged from road debris like rocks etc... We opted for the Type III Hard Anodizing over the Type II color anodizing which is only aesthetics for this purpose only (even though it cost us considerably more to anodize Type III than Type II). We started using the Type III Hard Anodized Black finish on our rally car customer's FMIC's years ago. Rally cars go through tremendous amounts of abuse and it was quite common to take hits on the intercooler from debris on the course. In fact after 1 event, we would often see a large portion of the intercooler fins bent (killing efficiency) and fixing them was after each event was quite tedious. After the Type III Hard Anodizing, we notice a big difference as there was considerably less damage. Even after hits and even accidents, the FMIC could take more abuse than before. Testing has shown no noticeable ill-effect from the Type III Hard Anodizing on performance (regular spray paint etc... has shown ill-effects on performance). Eventually, we started utilizing the same Type III Hard Anodized Black on our street cars and now on our FMIC applications.
Quality is very important to us. We do extensive R&D as well as beta testing to ensure this (as some of you may already know, waiting for us to release the production units). We only release our products once we feel we have reached perfection. We do not rush to get our products out even if there is alot of potential customers. Also, we do quality checks before the intercoolers are packaged. EVERY FMIC is pressure tested to 50 PSI of pressure before they are shipped to ensure no leakage. We include detail instructions and ALL parts needed for installation. All our FMICs are backed with our Limited Lifetime Warranty.
We go through extensive R&D to test all the innovations and features we incorporate into our intercooler systems. With years of experience building race cars and high power street cars, you can be sure that you're getting the best!
CAUTION: This product is intended for OFF ROAD USE ONLY. Not legal for use on pollution controlled vehicles upon public road/highways. THIS PRODUCT IS FOR SALE FOR ALL 49 STATES EXCLUDING CALIFORNIA.