Aftermarket Bumper Air Flow Mods - Dodge Cummins Diesel Forum
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post #1 of 10 (permalink) Old 07-21-2019, 09:11 PM Thread Starter
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Aftermarket Bumper Air Flow Mods

This is a follow up from my towing temperature thread. This is a Steelcraft bumper. Long story short, I dont like how hot the truck runs with the bumper installed. I also got a CAC code (P027A) which I think is caused by low airflow across the intercooler. I set up a PID on my monitor to watch CAC temps today. I drove 75 mph for about 15 miles (not towing) and saw the CAC temp stayed about 20-30 degrees above ambient. Obviously the deltas were bigger when I slowed down around the neighborhood but I wanted to see what they were like at highway speeds since this is the majority of my use. These deltas seemed decent to me but I have no idea what the delta was with the stock bumper. Ambient temps were about 100F during the test this afternoon with light winds.

Mods:
1. I removed the 20 lightbar. The opening is directly in front of the top portion of the intercooler.
2. I cut two 3.5 holes on either side of the license plate.
3. I made an air deflector out of thin sheet steel and aluminum angle. This is mainly a test mock up because Im not sure if using this will help or hurt temps so Im going to try both ways. The install is definitely not permanent.

Here are some pics.

Before:


After:


Deflector plate:



Im going to do some testing with the deflector on and off and Ill report back tomorrow. Let me know if you have any questions.


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post #2 of 10 (permalink) Old 07-21-2019, 09:21 PM
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In this for curiosity sake.

How much of a difference if any did just removing the light bar make?

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post #3 of 10 (permalink) Old 07-21-2019, 09:46 PM Thread Starter
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Originally Posted by the man in black View Post
In this for curiosity sake.

How much of a difference if any did just removing the light bar make?


Lightbar removed made a very small difference, less than 5 degrees. Same route, same weather conditions.

Just got back from another test, this time with the additional 3.5 holes and the deflector installed and no lightbar. Now my deltas are down to 15-20 degrees. Ambient temp is down to 90-92F on this test. Winds are still light. Im thinking the addition of the two holes made a difference. A lot of air can go through those holes.

Im going to remove the shield tonight and run the test again tomorrow. Ill post up those results.


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post #4 of 10 (permalink) Old 07-21-2019, 10:36 PM
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Mount that ducting so it is below the bumper, make it a scoop.

The cooler the air going through the intercooler, the better for the engine power.

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post #5 of 10 (permalink) Old 07-21-2019, 10:46 PM Thread Starter
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Originally Posted by Ltngdrvr View Post
Mount that ducting so it is below the bumper, make it a scoop.

The cooler the air going through the intercooler, the better for the engine power.


Ill look at that idea. With the current design I was trying to force the air that goes through the lightbar slot and two 3.5 holes to go across the intercooler. Not sure its working


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post #6 of 10 (permalink) Old 07-21-2019, 11:27 PM
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Quote:
Originally Posted by Deerhunter4 View Post
Ill look at that idea. With the current design I was trying to force the air that goes through the lightbar slot and two 3.5 holes to go across the intercooler. Not sure its working


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post #7 of 10 (permalink) Old 07-21-2019, 11:28 PM
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Quote:
Originally Posted by Deerhunter4 View Post
Ill look at that idea. With the current design I was trying to force the air that goes through the lightbar slot and two 3.5 holes to go across the intercooler. Not sure its working


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Right, that's why I was saying to make it a scoop below the bumper, so it will force more air through the intercooler.

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post #8 of 10 (permalink) Old 07-21-2019, 11:32 PM
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You’re my hero. I’ve been meaning to do this, I guess I will too. I have the same bumper you do and got the cold air charge code a few times pulling even light utility trailer w 3 quads. I want to make some square holes where you did round or enlarge the light bar hole to the bottom xrosstube

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post #9 of 10 (permalink) Old 07-22-2019, 12:32 AM
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Quote:
Originally Posted by Deerhunter4 View Post
Im thinking the addition of the two holes made a difference. A lot of air can go through those holes.

GM found by hogging out the center of the bow tie emblem on the nose of the Z/28 (coining the term flow tie), they picked up 80 CFM across the radiator. And were talking about maybe, MAYBE, six square inches.

And the old 12v and 24v engines used to pick up what, about 15hp by drilling a few holes in the bottom of the air box...

Youre definitely on the right track making airflow work for you. Fluids always take the path of least resistance, so by giving it an easier way to get to/thru your intercooler, youre just giving it a way to be lazy in a manner that makes it most effective.

Interested to see how further testing and development works out.



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post #10 of 10 (permalink) Old 07-22-2019, 06:56 AM Thread Starter
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Update: Deflector removed: temps are down even more. Averaged about 12-17 degrees above ambient. One change that needs to be known is that the wind was blowing this morning. About 20 mph cross wind during this test. Temp was 70F.

Just FYI IAT run 25-30 degrees above the CAC temp so for every degree I reduce the CAC temp Im also reducing IAT. Seems obvious but I can verify.


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