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Discussion Starter #1
Hello Mini 2er's,

Just to let everyone know we have our very own Vecchio Engineering intercooler arriving shortly for the R53 Supercharged Cooper S Models. As soon as the first one is complete I will post up pictures! We have tested and experiment with various designs - however it’s a bit like reinventing the wheel. Without going into "geek" like detail and writing/copy pasting from the internet – lots of very good info available online, worth having a look. There is not a lot your can do - to create a replacement intercooler for the Mini. 1. It has to fit original location 2. Cores can be used vertically or horizontally. 3. Using bloody good cores if not the best. 4. Top quality parts, materials and craftsmanship! THAT’S IT! (Points 3. and 4. should be standard procedure anyhow)

This is where the controversy will start! The price will be ridiculously cheap compared to other offerings on the Market. It will at the very minimum perform just as well as the market leaders if not better!

Please post your thoughts on this. All I want is feedback from you guys who will be considering buying an intercooler for your R53 Cooper S in the future. I know you have not seen our product yet! However, do you have any issues or trivial niggles with current offerings on the market such as price, colours, size etc… Anything!

Feedback will be sincerely appreciated!

Kind regards,

Leo

Vecchio Engineering

Welcome to Vecchio Engineering - The BMW and New Mini Tuning Specialists
 

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Need more details of the product you will be selling...

Questions: Price? when available? what size? (details on any boost loss etc) come with air diverters? dyno/track/strip proven testing? Any testing - back to back testing against stock/other ICs as a comparison? Options for different colours? Whats it going to look like - stock / big aftermarket and your face / other ? What guarantees are to be provided with the IC? Fit with existing connections/boots?

More details are needed or is it still in its infancy ?
 

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Discussion Starter #4
Need more details of the product you will be selling...

Questions: Price? when available? what size? (details on any boost loss etc) come with air diverters? dyno/track/strip proven testing? Any testing - back to back testing against stock/other ICs as a comparison? Options for different colours? Whats it going to look like - stock / big aftermarket and your face / other ? What guarantees are to be provided with the IC? Fit with existing connections/boots?

More details are needed or is it still in its infancy ?
1. CNC billet elliptical ends (where rubber boots attach). Strongest possible solution.
2. End tanks on either side will be fully radius’d from rectangular shape to elliptical – for the best flow. This is the best way. No one does this because of costs apart from GRS.
3. PRICE: Sub £280(Inc vat).
4. Core size will be 50mm thick (subject to change though!) Size wise think GRS/Forge/JCW GP.
5. Cores used will be the most suitable for the Mini application. Cores come in infinite combinations of tube size and vane pitch. Not to mention bar & plate tube and fin. Will we test them all? No chance – product would never be launched otherwise!
6. Lots and lots of real good data out there on the existing intercoolers. Some can’t be discredited.
7. Initially no diverter will be offered when product launches. By diverter I mean the ones that fit onto the intercooler itself and or the underside of the bonnet. We MAY launch one after if subsequent data deems is spectacularly necessary.
8. We will more than likely have a diverter inside the inlet side of the intercooler and (GRS Motorsport) POSSIBLEY outlet side. (We will flow bench though!)
9. Intercooler is a stock replacement – like for like swap with OEM. We recommend new boots thought if the old ones look tired!
10. Light as possible! Less metal the better.
11. Colours are aluminium (natural finish), polished aluminium (extra cost) and powder coat (extra cost).
12. Looks wise – It’s going to look like an aftermarket intercooler – Probably GRS.

JCW GP intercooler is VERY, VERY, VERY, VERY, VERY, VERY GOOD – EXCELLENT INFACT! However I won’t be able to make it or sometime that resembles it. Simply because there is only 1 company in the world that makes that kind of core! I kid you not! I cannot go to them and say make me 5 cores! They would not even except an order of 5000 cores. Ever wondered why the JCW GP cooler looks so crude! (I know you guys know this already) All they’ve done in weld an extra few rows off another cooler. This leads me to the point, even with BMW’s limitless funds they did not deem it necessary to make a bespoke intercooler with bespoke tooling for the JCW GP intercooler – even though over 2000 were made and probably 20,000 units subsequently sold to standard Cooper S owners.

We played around with the idea of using aerospace, F1 type cores but get your cheque books out your talking ££££’s just for the core. Is there any point in buying the best core then putting it on top of the engine!

ISSUES!!!!

Bloody expensive tooling has to be made for the end tanks – 2 tools required! One for each end. Tools have to be made anyhow for the initial first one I am making. If I had used “box tanks” I can afford to play around with them more! My intention is to press the tanks out in one piece! Its touch and go if we can get away with this.

TESTING!

I am happy to provide the intercooler once built for testing. I’m not going to be a knob and say you can only test on X, Y & Z. I’ll let you guys decide what, how where and when to test. Not bothered about chassis dynos or who they belong to. All I ask is I’m present on the day. OK!

I will promise you though it will look and feel like a quality product. Fingers crossed it will perform too.

Kind regards,

Leo

Vecchio Engineering
 

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Discussion Starter #6

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Could have done the CNCd ends as extrusions them upset them to get the lip on the edge, maybe only needed 1 extrusion tool then.........?
 

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Discussion Starter #9
We looked at extrusions - yes. However, two tools were required for each end. Then they would need to be machined all the way around. Also two jigs are needed to hold them in the CNC machine. (one for each end). Does not save a lot in the end - works out more as more processes are involved!
 

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LEO I am happy to test a unit for you on my R53! I can make comparisons, and drum some sales up-in return for the unit.
 

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Discussion Starter #13
Same here would be interested, has it dead a slow death?. no updates since Aug
Lots of people have been very interested in the development of this new intercooler for the R53 S and have contacted me with various questions and useful information. Just to confirm to everyone THIS INTERCOOLER WILL GO AHEAD! we have been busy in the back ground working on other projects as well as this.

However, this is where we are at. We have now selected a suitable core design for the intercooler itself. Next step is to determine the core size - reason for this is the internal diverters at both the inlet and outlet of the cores. By early next week these issues would have been sorted and the 1st core can be made. After this, 3D models can be drawn of the one piece (maybe 2 pieces) end tanks and the internal diverters of the cores itself.

Incidentally, if I haven’t explained myself that well I’ll try again. When I say diverters at both ends I mean the diverter the GRS “Motorsport" intercooler uses in the entry of the core. We will try and use a similar setup with a completely CNC’ed diverter at both ends. However, designing these is the tricky and time consuming part as they have to clear the side walls of the end tanks to be welded on. This is a doddle to do in the 3D world but we want the best possible design –this is the part proving harder to test and confirm.

Thanks again,

Leo

www.vecchio.co.uk
 

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LEO I am happy to test a unit for you on my R53! I can make comparisons, and drum some sales up-in return for the unit.
I think some independant testing would be better - i.e. not someone wanting a freebie in return for saying its excellent !! :lol:

Lots of people have been very interested in the development of this new intercooler for the R53 S and have contacted me with various questions and useful information. Just to confirm to everyone THIS INTERCOOLER WILL GO AHEAD! we have been busy in the back ground working on other projects as well as this.

However, this is where we are at. We have now selected a suitable core design for the intercooler itself. Next step is to determine the core size - reason for this is the internal diverters at both the inlet and outlet of the cores. By early next week these issues would have been sorted and the 1st core can be made. After this, 3D models can be drawn of the one piece (maybe 2 pieces) end tanks and the internal diverters of the cores itself.

Incidentally, if I haven’t explained myself that well I’ll try again. When I say diverters at both ends I mean the diverter the GRS “Motorsport" intercooler uses in the entry of the core. We will try and use a similar setup with a completely CNC’ed diverter at both ends. However, designing these is the tricky and time consuming part as they have to clear the side walls of the end tanks to be welded on. This is a doddle to do in the 3D world but we want the best possible design –this is the part proving harder to test and confirm.

Thanks again,

Leo

www.vecchio.co.uk
Thanks for the update. What is the latest likely timescale for these now ?
 

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Keano- We are NOT just after a "freebie"

This is an offer for Vecchio to have a proven and tested unit, which with our return feedback; would drum up masive sales for the company!

Especially being tested by die-hards MINI fans. And also being much cheaper than the compertition!

Ps, Vecchio I am more than happy to pay what you might want for a tester unit :)
 

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Seems a lot of 'just like GRS'. Is this likely to just be a blatant copy, and if so what is going to make it worth choosing it over a GRS?
 

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Discussion Starter #19
Seems a lot of 'just like GRS'. Is this likely to just be a blatant copy, and if so what is going to make it worth choosing it over a GRS?
This will not be a "blatant copy"! If it was I would of shown/launched the first prototype a long while ago. Instead we are looking to improve things if we can. The Vecchio Engineering intercooler will be extremely competitive on pricing – however, this will not mean compromised or substandard parts, components or workmanship. I have mentioned the Forge and GRS intercoolers as they are the most widely available and recognised in Europe.

www.vecchio.co.uk
 

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Keano- We are NOT just after a "freebie"

This is an offer for Vecchio to have a proven and tested unit, which with our return feedback; would drum up masive sales for the company!

Especially being tested by die-hards MINI fans. And also being much cheaper than the compertition!

Ps, Vecchio I am more than happy to pay what you might want for a tester unit :)
Fair enough dude - you see my point though Im sure ;) Real results are what we want afterall...
 
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