Warm air intake (wai) with controller all mechanical

[gumby79]

Thire is much talk of a WAI (worm air intake) and how it could be done , but alas the idea seems to get stalled when the power loss /loss of FE (Fuel Economy) form uncontrolled IAT. To cold / hot is bad for economy. Cummins stats 1%power loss per 10°f above 60°f. EG , A 250HP diesel will produce 240HP with the same fuel demand as 250HP at 90°f IAT (Intake Air Temperature) this is measured at the intake manafuld. So hears my Idea for controlling the IAT with a WAI
The old low tech.answer is found in the carburetor /TBI (Throttle Body Injection) air cleaner.

A bi metal adjustable thermostatic Vac.(vacuum) Switch








Air cleaner part number from my insperation a 1974Ford E100 Econoline .


The TBI is purely thermal mechanical on a '94 454







I need 2 454 snorkels or build my own custom to handal the air demand of pulling heavy grades at down to -40°c/f . This is intinded to mix the air hot with cold. To keep it in the happy zone 32° f-60° f.
Will update when I get parts to work with.
Suggestions welcome

Gumby stay flexible.

[Xist]

I italicized the words that confused me. I am honestly just trying to make sure I understand.

Warm air intake (wai) with controller all mechanical
There is much talk of a WAI (warm air intake) and how it could be done , but alas the idea seems to get stalled when the power loss/loss of FE (Fuel Economy) from uncontrolled IAT. Too cold / hot is bad for economy. Cummins states 1%power loss per 10°f above 60°f. EG. A 250HP diesel will produce 240HP with the same fuel demand as 250HP at 90°f IAT (Intake Air Temperature) this is measured at the intake manifold. So here's my Idea for controlling the IAT with a WAI
The old low tech.answer is found in the carburetor /TBI (Throttle Body Injection) air cleaner.

A bi metal adjustable thermostatic Vac.(vacuum) Switch

Sounds good to me! In theory, couldn't you use this technique to open vents on smooth wheel covers if you need to brake hard?

[oil pan 4]

http://ecomodder.com/forum/showthrea...ake-33039.html

[gumby79]

mechanical: me·chan·i·cal
məˈkanək(ə)l/
adjective
1)working or produced by machines or machinery.
"a mechanical device"
I mean non electric
warm: wôrm
adjective1) of or at a fairly or comfortably high temperature.
"a warm September evening"

As in not cold (down to -40°f/c is common winter for Montana, USA) and not hot as in Keep the IAT under 90° f @3% wasted fule. AIT between 60-90°f Costing Engine On through full throttle. Keeping the AiT =<ambient. It'll be summer MPGs in winter. Or hopefully an improvement.

From: frəm/Submit
preposition
1.
indicating the point in space at which a journey, motion, or action starts.

Too cold / hot: below 60°f above90°f

Intake manifold: In automotive engineering, an inlet manifold or intake manifold (in American English) is the part of an engine that supplies the fuel/air mixture to the cylinder.
There is a difference between inlet IAT, pre-turbo IAT,post-turbo/pre-Inter Cooler IAT, post-Inter Cooler AIT, and intake manifold the one closest to the intake valve is the one that counts.
Could you use bold in future as it is easier for me to see than italics with my eyes.
Hope this helps.
-----
Oil pan4 what were your setpoints open/close °f ?
Most of thease CARB air cleaners I've run across have been slow movers .5-3sec reaction times. Like a coolent thermostat when you test it on the stove. Is yours supper fast?

----I'm planning on using 2 snorkels or a custom hand fabricated system for the choking action youre speaking of under load. May end upsuing a damper door from an old A/C with this "brain".

Both of our engines are in excess of 350 cubic inches which is far exceeding the air flow capacity of a 2 inch diameter smooth tube ,and the corrugated flex hose is less. the hot-air side of this device is set up with1.25-2.5" most were 2" if memory serves.
My hot side needs as much flow as the cold. I am assuming that @-40° pulling Elk_Park_Pass I'll need it With a dT of 100°f.

Gumby stay flexible

[oil pan 4]

The mechanical thermostatic valve is mechanical and regulates the air to around 90°F.
The electric portion only reverts it to cold air.
You don't have to use the cold air.
I thought about restoring the OE thermostatic intake but I wanted something a little different.
Main difference with mine is I was never trying to flow full air flow through the WAI.
If I need power the CAI is opening.
Also I am going to be running 11:1 compression.
I will end up using 2 snorkels too.

If it gets so cold there why not just convert to an after cooler and just turn off the after cooler when it's really cold letting the turbo heat the air? While drawing air from under the hood.
That is what I was going to do when I thought I was moving to Montana or Wyoming.
Have you read the 5.9 stationary non intercooled application manual?
They recommend running cold air down to 25°F to freezing, then drawing air from inside the enclosure if operated below 25.

[gumby79]

If it gets so cold there why not just convert to an after cooler and just turn off the after cooler when it's really cold letting the turbo heat the air? While drawing air from under thehood.

My ambient temperatures range from -40°f/c,winter in Mt. to 120°f+ in Las Vegas,NV in summer.
The problem I have is when the turbo isn't producing heat. normally 55mph 1-3psi 450-650EGT.this took 15mi to open the thermostat this evening @~ 43°f
Both are called aftercoolers(after the turbo) and the mistakenly and accepted both are called Intercooler (means inbetween compound turbos) Cummins calls them both Charge air Coolers. Dodge called the water jacket an after cooler. And the air to air an Intercooler on the valve covers, and the name has stuck.
When I considered running a water jacket ,I lived 50mi north of Portland Oregon, from an early 1ST generation pre 91 . But decided agenst this as it would heat the air to 160-200°f in the water jacket IC. Resulting in a 10-14% loss of 16-24HP of 160HP rated ,and increased fuel use at all ambient temperatures. And add a severe heat load to the engine Coolent system wile climbing grades. Costing Neutral for 3-5mi continuous yealds 50-150°f EGT below idle and coolant20- 30°f below thermostat of 175°f at the bottom of 3 different grades from radiant block cooling.


---- this system is not a purely winter item. We got 2-4 "of snow and below freezing yesterday (4/29/16) spring has sprung but still gets cold . So it will need to add heat on downgrades/ light loading and pull heat on upgrades/ medium loading.

[gumby79]

Originally Posted by Xist

Sounds good to me! In theory, couldn't you use this technique to open vents on smooth wheel covers if you need to brake hard?

Thank you
As for wheel covers it would take some creative work and dynamic balancing. But yes.
This gave me an idea. Grill shutters could also be run , using Vac. accurated A/C door dash pots and the right thermostatic Vac . Switch, the larger diaphragm has more leverage and longer strokes available.
Gumby stay flexible

[oil pan 4]

The air to water coolers run on their own coolant circuit.
Air to water coolers can cool almost as well as air to air.
Who runs the air to water cooler in with the engine coolant loop?
For my diesel I plan on putting an air to water cooler between the turbos and that coolant is going to be on it's own coolant loop.

[straight5]

These are somewhat plentiful at salvage yards.
I don't know all of the models had them, but I know some of the FWD naturally aspirated Volvos did.
Just a simple plunger type.
Volvo Airbox Thermostat Valve AFTERMARKET 103083 CAL-1266826

[cRiPpLe_rOoStEr]

Some Chevy trucks with the 292cu.in. straight-6 were factory-fitted with a selectable cold and warm air intake.