GR Yaris Milan's GR Yaris Track build

[MilanGRY]

Dedication and focus. Do you know how much the PWR intercoolers weighs?

Thank you ! The stock intercooler weighs 3.2 kg while the PWR weighs 5.4 kg. Most of the difference is from the endtanks, the stock one being made out of plastic and the PWR out of cast aluminium.
Most aftermarket intercoolers for the GR Yaris that I have seen are somewhere around 7-9 kg.

 

[MilanGRY]

Finally making an update on this thread. I had a lot of stuff going on with my other cars but still continuing on my auxiliary radiator project.

I have recieved all Gen2 parts for the Aux Radiator including all brackets and lines. But i quickly found out that I cant reuse the brackets, as the Gen2 bumper protrudes much more forward than the Gen1, so that means much less space for me. That also means I can't use the Gen2 side exit, so I will vent the air out to the wheel well and will plan to use the Aero Package fenders to extract the air out.

So I 3d scanned the Gen2 Aux radiator and started designing brackets to make the whole package fit. It did take a few versions until I was happy with the position with the radiator, in the end i tried to move the radiator as much to the end as possible to have space to make an efficient inlet duct.

Here are the brackets that I came up with :

And here is the prototype thats 3d printed :

The Gen2's radiator is mounted solid to the car. On my design I used small rubber bushings on all the mounting bolts on the radiator, to dampen the vibrations a little bit, especially since I am running Verkline engine mounts on my car.

The FDM 3D printed brackets were obviously only for testing, they are too weak to be used on the car, which meant I took the opportunity to try out SLM 3D printing. I used a service to 3D print my brackets out of stainless steel and they came out perfect.

I then started designing the front inlet that attaches to the bumper. I already made a rough mockup, thats featured in an earlier post, but I designed it now new from scratch. The inlet will be molded to the foglight housing. I did modify the housing by grinding the surface flat.
Below is a 3D printed prototype in blue for a better visualization :

The whole concept looks really promising and I'm excited to test it out soon.
Right now i'm further tweaking the inlet and designing a duct that sits between the bumper and the radiator. After that I just need to design the exit and hook up all the lines.

 

[Amjad]

The work on that getting that radiator integrated is awesome

 

[MilanGRY]

Finally starting to see light at the end of the tunnel.

I'm almost ready to start printing the final versions of the ducting of my aux radiator.

The front inlet duct is basically 95% finished. I only need to tweak the design of the duct as a 2-piece to fit a mesh inbetween to protect the radiator.

And the design for the wheel well vent is finalized. Hopefully I will 3D print the final version this weekend.
This one took a lot of time to draw up, I had to start 3 times over from scratch, as I had fitment issues due to the complex shape of the OEM wheel liner.
But now it fits like a glove with no gaps and the design itself came out properly well.
The vent is designed to guide the air downwards and out of the wheel well to reduce drag.

I have decided to change directions with my cooling setup and use the auxiliary radiator the same way as the Gen2 to add cooling capacity.
My initial plan was to connect a heat exchanger to it which cools the engine oil, but there isn't quite an efficient way to mount the heat exchanger in the engine bay.
The main problem is the way the oil filter housing is designed. The oil cooler line routing wouldn't work well and designing a new oil filter housing is too much work for now as I have a lot of other things planned to improve on the car.

Unless I would get access to the Rally2 oil pan but that seems difficult to source.

So now the plan is to fit an air to air oil cooler to the other side of the bumper with the same style of ducting like the auxiliary radiator that im doing now.

 

[tonic]

That’s some seriously clean CAD work!

Rally2 engine has a pretty aggressive rearward lean. I’m not sure the sump would actually work if you kept the engine in its stock orientation.

 

[GRandemakina]

Amazing work going on if you ever consider to commercialize an "Aux Radiator Install Kit" for Mk1... I think would a be a good market for it.

 

[MilanGRY]

That’s some seriously clean CAD work!

Rally2 engine has a pretty aggressive rearward lean. I’m not sure the sump would actually work if you kept the engine in its stock orientation.

Thanks a lot tonic!

Yes it definitely wouldn't work if I just bolt it on.
But I don't think it would be too much work to cut the pan and correct it and make a new oil pickup.

Amazing work going on if you ever consider to commercialize an "Aux Radiator Install Kit" for Mk1... I think would a be a good market for it.

Thank you! I did think a few times if I should commercialize on my cooling project.
But its not really a plug & play solution as it is quite labour intensive, the bumper needs a lot of cutting where the foglight is mounted and there needs to be rivnuts inserted on various places.
Also price wise I think it would end up too expensive. Airtec has a kit already thats very good priced.
I think if I would sell my kit, the price would easily be triple of that excluding the OEM parts needed.

But if there are enough people interested for it, I would be open for it.