You could just take the 6" hole saw to your fender like I did

 

I've been working on the KB cooling system a bit. I added three temp sensors in the system to get some data on what is actually happening so I'm not blindly spending money on upgrades.
Sensor 1 - in coolant reservoir for baseline reading and IC in temp
Sensor 2 - in inlet of heat exchanger for IC out temp and baseline for HE temp drop
Sensor 3 - in outlet of heat exchanger for HE delta
I am logging all three sensors in HPT thru the EIO.
First a voltage divider circuit is needed to get the actual voltage drop across the sensor to HPT.


Sense NTC sensors are non-linear, a polynomial equation has to be created for HPT to use the sensor voltage to output temp. I had to reduce the data range in order to get the curve accurate in the operating temp range.


For the sensors themselves, I used 8mm NTC sensors and used nut-serts with some sealant to install them in the HE and CR.

 

Any word on data collection? This is good stuff!! Thanks Kenny.

You should figure out a way to tap the water going into and out of the blower to gather the same data there.

 

All the data I have to this point is in the intercooler thread in Forced Induction. Basically my HEX does squat.

Where the current sensors are placed I am getting the IC in/out sans heat gain/loss from the lines. Res out = IC in and HEX in = IC out. I have contemplated adding sensors to the IC but I think they actual manifold heat would plus the packaging would introduce un-necessary leak points.

There are a few more tests I want to run with ice water and an open grill but I think I am going to go ahead and pull the trigger on a new HEX to see what that does. I was able to get my proposed design mocked up and got all the mounting points and fitting locations ironed out.

 

Cardboard cutout of proposed HEX design being test fitted...



Comparison of new design to current setup. New HEX is 2.55x the frontal area of the current one and 1" thicker core.



I am also thinking of opening up the HD grill for my own version of the Z/28 'FlowTie'. Just the BowTie area is 34sqin. I am also thinking of opening the center of the bar on either side of the BowTie which is another 16sqin. The blue tape represents areas that can be removed.



Back of grill for reference of what can be cut out...

 

I really think the intercooler is your problem and not the heat exchanger in the front.

 

his data shows the HX is doing nothing....in and out are basically exact. how can the intercooler do its job if you're feeding it with a HX that is doing squat?

looks like the same HX i have. now you have me wanting to add temp sensors to mine LOL.

 

I agree... if the HX is doing nothing it certainly wont hurt to upgrade it.

 

Yea I just went back and reread that thread. Upgrading the HEX will help overall I think, but I would bet he is still going to have massive temperature rise during a run. Pat's case is an exception or he goofed it up somehow

 

I agree with you Richard, the IC is surely an issue but currently the system is continually gaining heat. The water is gaining heat, although minimal, between the res-out and hex-in so I have to presume the IC is responsible for that, not just engine bay heat thru the lines. The HEX is not able to keep up with even this small heat gain to keep hex-out around ambient so again I have to presume a new HEX would provide a benefit.

Here is the final revision I am sending out for quotes...