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Originally Posted by Chuck33079 After having looked at the OEM aliminum crash bar and my GTM intercooler, I'd have to give the edge to the intercooler as a structural support.

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Old 03-05-2014, 09:59 AM   #1 (permalink)
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After having looked at the OEM aliminum crash bar and my GTM intercooler, I'd have to give the edge to the intercooler as a structural support. The OEM bar is just boxed AL, right? If that's the case, the IC will hold up better since it's got an internal structure to add some strength, right?
I believe the OEM crash bar is designed to direct force around the front of the car and down the frame (i.e. the length of the car). Look at how and where it attaches. There is no doubt in my mind that an intercooler will not perform as well in a crash as the factory, engineered crash bar.
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Old 03-05-2014, 10:04 AM   #2 (permalink)
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I believe the OEM crash bar is designed to direct force around the front of the car and down the frame (i.e. the length of the car). Look at how and where it attaches. There is no doubt in my mind that an intercooler will not perform as well in a crash as the factory, engineered crash bar.
I have looked at it. That's why I think it'll function quite well as a crash beam. It mounts to the same locations, and the internal structure of the core is going to give it more intenal support than the OEM bar assuming that's just square aluminum. I haven't seen one cut open, so I can't say that for sure. Then the only difference would be the slight curve of the OE bar as compared to the flat IC, right?

Obviously we'll never know for sure since nobody's about to crash test these things.
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Old 03-05-2014, 10:15 AM   #3 (permalink)
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Obviously we'll never know for sure since nobody's about to crash test these things.
Let's hope at least!

I think one potential issue is the fact that the ICs are a bunch of welds holding various parts together (end-tanks, core, etc), whereas the crash beam is a contiguous piece of metal. The welds are going to be the weak point in the ICs I suspect. As soon as one lets go, then the force vectoring of the IC in a crash would be toast. It's one of the primary reasons I elected the GTM kit, since it keeps the crash bar. Unfortunately, that decision hasn't really panned out.
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Old 03-05-2014, 10:26 AM   #4 (permalink)
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Let's hope at least!

I think one potential issue is the fact that the ICs are a bunch of welds holding various parts together (end-tanks, core, etc), whereas the crash beam is a contiguous piece of metal. The welds are going to be the weak point in the ICs I suspect. As soon as one lets go, then the force vectoring of the IC in a crash would be toast. It's one of the primary reasons I elected the GTM kit, since it keeps the crash bar. Unfortunately, that decision hasn't really panned out.
Sorry Sashsa for this thread jack...

However, weld material is always stronger than the base material (assuming the welder used the correct rod). When welding A992 (50ksi) material we call out a E70 rod which has a yield stregth of 70ksi, this is welding 101 and required by AWS D1.1 Structural Welding Code. If a weld is done properly than the material around it will yield first. That's why all of us structural engineers prefer to weld everything. You basically weld it and forget about it.
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Old 03-05-2014, 10:44 AM   #5 (permalink)
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This has nothing to do with how strong the material is. The intercooler could be a two in thick plate of steel and still would get pushed into the engine that would get pushed into the bay, if it wasn't attached to the frame.

The crash bar designed and bolted to the frame. On impact that bar takes the energy and puts it to the frame of the car therefore consuming the energy around the driver. The frame is a thousand times stronger than any intercooler. The car frame is rigid and you keep your legs.

Not saying the IC wont help, but it will be of minimal help to your body at high speeds.

Ok..lets get back to turbos!!
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Old 03-05-2014, 10:55 AM   #6 (permalink)
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This has nothing to do with how strong the material is. The intercooler could be a two in thick plate of steel and still would get pushed into the engine that would get pushed into the bay, if it wasn't attached to the frame.

The crash bar designed and bolted to the frame. On impact that bar takes the energy and puts it to the frame of the car therefore consuming the energy around the driver. The frame is a thousand times stronger than any intercooler. The car frame is rigid and you keep your legs.
But the IC is bolted to the same framerails that the OE crash beam is. At least mine is.



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Ok..lets get back to turbos!!
Agreed.
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Old 03-05-2014, 11:33 AM   #7 (permalink)
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But the IC is bolted to the same framerails that the OE crash beam is. At least mine is.
Oh snap! I was unaware this kit is designed to bolt onto the frame.

Well in that case it would help much more than the usual top single bolt. But not "as good" as the oem bar. But still I would feel much better about this with that design.

Damn this kit! Why cant I find flaws!..lol .. This is really an engineering marvel.
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