[MINIMANIAUK]

INTERCOOLER DIVERTER W/SPRAY HEADS - MINI COOPER S 2007+
MINI Cooper S R56 Intercooler Air Diverter with Dual Spray Head's
After being overjoyed that the new R56 MINI had a front mount intercooler we quickly discovered it's shortcomings. The R56 MINI's small intercooler suffers because it is located below the front lip of the bumper therby restricting roughly 50% of the frontal airflow. It also suffers significant airflow loss over the sides and bottom of the intercooler as well. Being who we are we knew there was a simple solution to maximize the R56 MINI's intercooler efficency. We first created an air diverter for the MINI's intercooler that grabs 50% more air from the lower grills airspace and directs it into the intercooler. Next we added sides plates to our diverter to capture the escaping airflow from the sides. After this we focused on the bottom of the intercooler. Using a high density foam insert we are able to stop airflow loss at the base of the intercooler. These modifications solved all of our air loss problems and made for a drastic reduction in intercooler temps but we decided to go even further by adding dual spray heads to the intercooler air diverter. By using the rear wiper pump the intercooler gets a nice spray of fluid allowing the evaporative effects to really have a significant effect on recovery rate when things really heat up. For 2007+ MINI Cooper S Coupes.

[MINIMANIAUK]

AND
Click Image for Larger View
INTERCOOLER MUFFLER DELETE PIPE - MINI COOPER S 2007+
MINI Cooper S R56 Intercooler Muffler Delete Pipe
When Madness found this part on the new R56 MINI Cooper S we couldn't figure out what this was. After doing some research we discovered that this was an intercooler sound muffler. Personally we think the MINI needs more volume not less. When we removed this piece, we disected it and found many chambers used to baffle the exhaust volume. A negative effect of this design is that it creates a lot of turbulence as the charged air passes through the muffler. This in turn slows down airflow in this area allowing volume to be absorbed in the chambers and also increases heat. By replacing your factory intercooler muffler with our delete pipe, quicker boost responce can be acheived and also slightly more turbo volume can be heard. Another side benifit from our muffler delete pipe is that less turbulence means less heat. Less heat means a cooler more dense air charge resulting in more power. Using our Intercooler muffler delete pipe we recorded 3-5 degrees temperature drop on the pre-intercooler pressures. For 2007+ MINI Cooper S Coupes.

[Avantone]

Look good - are they relatively straightforward to fit? and is the diverter obvious when looking at the car when fitted?

Avantone

[Benny No.1]

Intercooler divert thing looks interesting. Any links to your website yet?

[MINIMANIAUK]

INTERCOOLER DIVERTER W/SPRAY HEADS - MINI COOPER S 2007+
Should be on the UK site tommorrow, there will be more 07 items coming on line shortly

[Avantone]

There's more detail here including a video of the water-spray:

2007 MINI Cooper S Turbo - Engine Performance

Thing is, before I'd commit myself I'd want to know if they actually make any measurable difference to performance - I presume these are tested prior to marketing .

I'd also like to know what audible difference the delete muffler had (similar debate going on NAM)

Avantone

[n5290066]

Minimaniauk, I like the idea of the airflow diverters, but is there a better intercooler tha can be fitted. I've had a look and its pretty tight, but clever design always finds a way. Addiionally, is it possible to grill the front apron to allow some cool air down there. Larger, more efficient intercoolers seems to always add torque to turbo'd engines.

With your re-designed airflow, have you measure the improvement in KW or Nm?

I did not know that BMW had placed an intercooler muffler??? that clearly would restrict the charged air and heat it up. Is it able to be fitted without dealers dodging their guarantees?

Steve

[Pentagon]

I had Forge try and build an intercooler for my R56 MCS, they had the car for two weeks and made many tests concluding that there wasnt room for a worthwhile intercooler and the one on it was efficient. Forge did build me a blow off valve tho'.

I have bought both the divert and the muffler items that Mini Mania list for my car and will report back the difference. It already has a superb exhaust and an air induction and is booked in for the ECU part of the JCW pack as well as a manifold.

240 Hp no worries

[Japper]

Quote: Originally Posted by Pentagon (original)

I had Forge try and build an intercooler for my R56 MCS, they had the car for two weeks and made many tests concluding that there wasnt room for a worthwhile intercooler and the one on it was efficient. Forge did build me a blow off valve tho'.

Strange then that they do a far bigger intercooler for the 207GT / GTI if indeed this one is 'Efficient'

More likely they just didn't have room to fit a bigger one.

[n5290066]

Quote: Originally Posted by Pentagon (original)

I had Forge try and build an intercooler for my R56 MCS, they had the car for two weeks and made many tests concluding that there wasnt room for a worthwhile intercooler and the one on it was efficient. Forge did build me a blow off valve tho'.

I have bought both the divert and the muffler items that Mini Mania list for my car and will report back the difference. It already has a superb exhaust and an air induction and is booked in for the ECU part of the JCW pack as well as a manifold.

240 Hp no worries

Thanks Pentagon, its good to know somebody has had a go to beef up the size of the intercooler. Since you've done teh research it looks like the only other way to go would be a water cooler intercooler. I am no expertthough, so if somebody out there can let me know if this going to be more efficient or not i'd appreciate it.

Pentagon, the divert item you mentioned, is that the new intercooler divert which gets rid of the intercooler muffler? It seems to make sense rather than restrict the flow and looks like it would add a few herbs to the stew.

[Pentagon]

Quote: Originally Posted by n5290066 (original)

Thanks Pentagon, its good to know somebody has had a go to beef up the size of the intercooler. Since you've done teh research it looks like the only other way to go would be a water cooler intercooler. I am no expertthough, so if somebody out there can let me know if this going to be more efficient or not i'd appreciate it.

Pentagon, the divert item you mentioned, is that the new intercooler divert which gets rid of the intercooler muffler? It seems to make sense rather than restrict the flow and looks like it would add a few herbs to the stew.

G day my Australian friend, I lived in oz for 4 years and was Mini Australia best customer ( i had 5 in 18 months) for a while. In fact the mini salesman in Sydney ( Shaw Harrison) and I are still great friends. he now lives in Brisbane.

K & N and Forge motorsport had my car at their HQ's and did many airflow/ temp and intercooler tests. They said the intercooler is big enough its just that the bits in front are a ' little' obstructive. As for water spray it really isnt needed but will look amusing...I've got both bits that mini mania supply but i didnt get it from them , one is a air divert shovel looking thing with water jets that goes under the front intercooler, the other is the turbo muffler bypass baby bazooka tube. I've also got the blow off valve. none are yet fitted. I've got rolling road reports for the air intake ( + 5hp) and the exhaust ( incredibly + 22 HP)

[n5290066]

Pentagon,
You got an extra 22HP out of the exhaust? Wow
I am currently waiting for the new JCW kit to be fitted to my MCS. I am waiting to see how that pans out prior to fiddling with the mapping related to boost. I am also looking at doing something similar to the GTT Stealth dump pipe Cat convert. I just need to be careful so BMW don't go and get all worried about the changes.

The JCW kit apparently mods the air box as well.

[msh441]

Quote: Originally Posted by n5290066 (original)

The JCW kit apparently mods the air box as well.

Really? I was told by my dealer it was a cat-back pipe, panel filter and ECU map.

[Japper]

Well obviously Forge didn't try hard enough to design a larger intercooler that would fit.

Check this one out from RMS.

[n5290066]

Quote: Originally Posted by Japper (original)

Well obviously Forge didn't try hard enough to design a larger intercooler that would fit.

Check this one out from RMS.

+

Japper, does that all fit under OK? Also do the pipes fit OK so all that stuff doesn't need to be modded? Also, what extra capacity does that IC offer?

Sorry about all the questions mate.

[Japper]

Quote: Originally Posted by n5290066 (original)

+

Japper, does that all fit under OK? Also do the pipes fit OK so all that stuff doesn't need to be modded? Also, what extra capacity does that IC offer?

Sorry about all the questions mate.

Sorry, can't answer any of your questions, but looks to fit as standard.

I found this picture on BMW MINI Technikforum • Foren-Übersicht but can't read German

C.

[Japper]

Can now, found their site and it looks to fit without mods.

Together with their remap they're stating 234ps and 330nm

RMS Fahrzeugtechnik Dagn KEG - Home

[Xray'dit_Mini]

Quote: Originally Posted by Japper (original)

Well obviously Forge didn't try hard enough to design a larger intercooler that would fit.

Check this one out from RMS.

that isn't an r56....at least that doesn't look like my engine

[Japper]

Quote: Originally Posted by Xray'dit_Mini (original)

that isn't an r56....at least that doesn't look like my engine

That is a R56, but with a few mods. Looks like bigger turbo and lots of silicone boost tubes etc.