A Matheson gas technician...
A Matheson gas technician loads 10 pounds of liquid carbon dioxide into Design Engineering’s CryO2 cylinder. No, we’re not getting ready to serve up cold beers. CO2 is the cooling agent at the forefront of DEI’s in its Intercooler Sprayer Kit—a bolt-on blast of super frost that radically lowers a supercharged Mustang’s intercooled air.
It's no secret, nor is it by accident that a majority of our tech reports focus on engine/drivetrain-performance upgrades for late-model Mustangs. Handling and braking improvements also get love on these pages, but we admit the bulk of our mods coverage focuses on horsepower and ways of making more.
The aftermarket is chock full of individual bolt-on parts and multi-leveled systems designed for making the big steam we covet. Bits that enhance intake airflow, volume, or air temperature are the go-to components for generating that sacred horsepower. When taking a closer look at the nuances of intake air for our Mustangs' powerplants, we've learned that increased density is a major criteria for posting big power numbers at the feet.
Power adders such as nitrous oxide, as well as forced-induction systems like turbochargers and superchargers, are the popular methods of simultaneously increasing a Mustang engine's intake-air density and volume. A fast, cold air charge basically mixes with fuel and allows more oxygen to enter the combustion chamber, which in turn promotes a more-powerful combustion event by eliminating the pre-ignition that is a byproduct of increased cylinder pressure. The result, of course, is more horsepower, which we all agree is good.
DEI’s CryO2 kit includes everything...
DEI’s CryO2 kit includes everything necessary (10-pound tank, brackets, solenoid, stainless-steel braided supply line, arming, activation and WOT switches, fittings and intercooler sprayer) for a clean installation that can be accomplished in about two to three hours.
Intercoolers of air-to-air and water-to-air design are common additions to the aforementioned forced-air systems. The 'coolers serve as heat sinks, which dissipate heat from discharge before that air enters an engine. The water-to-air unit's ability to use ice as a method of super-cooling the water that passes through its core makes it a tremendously efficient device for lowering temps and promoting denser air. By comparison, the air-to-air systems work well, but because of their traditional front/grille-mounting location on a 'Stang and their dependency on ambient air, non-chilled 'coolers are really behind the eight ball when it comes to dramatically reducing intake-air temperature -- especially on searing days.
Enterprising 'Stangbangers use small shots of nitrous oxide plumbed into the intake airstream of their supercharged Steeds as a way to give air-to-air 'coolers a little help and eek more horses out of their blown combinations. While it's a method that certainly does work, we recently conducted a cold-air test that highlighted another process, namely spraying liquid carbon dioxide directly on an air-to-air intercooler's core.
Design Engineering Incorporated's CryO2 Intercooler Sprayer Kit (PN 080108; $541.52) brings this CO2 "freeze" technology to supercharged 'Stangs in the form of an all-inclusive package designed for small- or large-sized, air-to-air intercoolers. The kit, which we installed and worked with at GTR High Performance in Rancho Cucamonga, California, actually proved to be a more-effective, cost-conscious strategy for improving the intercooler's efficiency.
So that's your brief overview of the details that lie ahead in the following photos, captions, and dyno and temperature information. Read on and learn how cryo cooling is a great option to consider (over nitrous) for your blown Pony's air-to-air 'cooler.
Horse Sense: When it comes to pre-'11 Mustangs, just trying to keep up with the mega-impressive Coyote 5.0s is becoming a tall order. As many of you know, thanks to the addition of Fox and '01 Bullitt project 'Stangs, our pre-'11 upgrade game is pretty tight. So while keeping up definitely isn't easy at this stage in our wonderful hobby's life, believe we're now working harder to stay on top of the latest and greatest for late-model 'Stangs.
Oscar Zavala’s ’01 GT is our...
Oscar Zavala’s ’01 GT is our test bed for the intercooler sprayer. The Pony is sickeningly clean, and makes great power with only a simple assortment of bolt-ons and Vortech’s air-to-air intercooled SC-Trim supercharger.
The aluminum intercooler spray...
The aluminum intercooler spray bar and solenoid are the primary action components in the CryO2 system. The valve regulates the carbon dioxide, which is sprayed onto the intercooler through tiny orifices that are drilled around the entire perimeter of the spray bar.
The aluminum intercooler spray...
The aluminum intercooler spray bar and solenoid are the primary action components in the CryO2 system. The valve regulates the carbon dioxide, which is sprayed onto the intercooler through tiny orifices that are drilled around the entire perimeter of the spray bar.
DEI includes a pair of stainless-steel...
DEI includes a pair of stainless-steel bottles brackets with each Cry02 kit. The 10-pound bottle is installed in the 'Stang's trunk in the same fashon as a nitrous-oxide bottle.
Ricardo Topete mock-fits the...
Ricardo Topete mock-fits the intercooler sprayer before attaching the solenoid, running lines, and so on. The spray bar mounts on the front of an air-to-air intercooler, and must be installed in the small wedge space between the ‘cooler and bumper. A little trimming may be necessary to ensure a clean fit.
After trial-fitting the sprayer,...
After trial-fitting the sprayer, Ricardo installs the CryO2 solenoid on the spray bar, using Teflon tape to prevent CO2 leaks at the solenoid.
Once the solenoid is fitted...
Once the solenoid is fitted on the 19x9-inch spray bar (also available are 8x4-inch and 16x5-inch spray bars), the assembly is pushed into position. DEI provides a set of stainless-steel straps that are used for securing the bar to the ‘cooler. We found the fitment was tight enough without using the straps.
Like the CO2 bottle, the 14...
Like the CO2 bottle, the 14 feet of braided supply line is installed in similar fashion to a nitrous unit’s feed line: below the Mustang, following the passenger side of the chassis.
The CryO2 unit is triggered...
The CryO2 unit is triggered by a 12V arming switch. Ricardo mounts the toggle in the ‘Stang’s center console, just in front of the shifter and within Oscar’s easy reach.
Wiring logistics start with...
Wiring logistics start with power and ground for the arming switch and solenoid, of course, and deciding how the system will actually be triggered. A WOT microswitch is supplied, as is a momentary button, which DEI suggests using as a primer activator. We elected to use the momentary button, which will allow Oscar to fire the CryO2 blast at his discretion.
Here’s a closer look at the...
Here’s a closer look at the standby/armed toggle switch and the button that’s pressed to deliver the super-cool CO2 burst on the intercooler.
The CryO2 system uses liquid...
The CryO2 system uses liquid carbon dioxide that’s actually stored at -80 degrees, which will no doubt put a serious frost on a supercharged ‘Stang’s air-to-air intercooler. The CO2 is readily available at any welding-supply location, like Matheson in Rancho Cucamonga, California, or at sporting goods stores where paintball guns are charged. Once the bottle is filled, make sure this warning sticker is applied. While CO2 is non-flammable, the gas can be lethal, as it can cause suffocation if it’s inhaled.
The intercooler’s CryO2-chilled...
The intercooler’s CryO2-chilled temperature was recorded with probes placed directly in the ‘cooler’s core. With the CO2 shot, air temp dropped by almost 20 degrees. 5.0
On the dyno, pre-CO2 air-temperature...
On the dyno, pre-CO2 air-temperature was measured using an infra-red heat gun, aimed at the super- charger head unit and then at the intercooler core itself. It’s interesting to note that air temp increased as much as 3 degrees between the head unit and the intercooler.
On the dyno, pre-CO2 air-temperature...
On the dyno, pre-CO2 air-temperature was measured using an infra-red heat gun, aimed at the super- charger head unit and then at the intercooler core itself. It’s interesting to note that air temp increased as much as 3 degrees between the head unit and the intercooler.