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M7 Direct Flow Intercooler 2 (DFIC2) System
Our Price: $899.00

We've heard it over and over: "I can't believe someone didn't invent an intercooler like this earlier!"

Only from the minds of M7 comes the patented technology of the M7 Direct Flow Intercooler 2 (DFIC2) that is truly unlike anything currently available. The original and best, the M7 DFIC2 intercooler breaks new ground in efficiency and thermal transfer capability.
Be sure it's an original M7 DFIC2:
• Lab tested with computational fluid dynamics (CFD)
• Extremely high thermal efficiency & heat-soak recovery
• Dual monitoring ports for boost/temp gauges
• Helps advance timing and stop detonation
• Features 5 cores (not just 3) for superior cooling
• Includes a custom fiberglass, gel-coated DFIC hood scoop for maximum performance (prep and painting required)
• Upgraded stainless hardware and foam package
• FREE custom silicone boots designed for easy install
• Features standard brushed aluminum finish


The new DFIC2 features an improved core design over the original DFIC. The intercooler's interior fins have been redesigned to allow for minimal back pressure, resulting in maximum airflow through the core. Thinner vertical and horizontal plates have also been utilized in the core to improve heat transfer over the previous DFIC design. This combined with newly designed interior fins helps increase overall efficiency of the intercooler. The DFIC2 recently tested and tuned on a car that now puts out 259 HP on the dyno! This number may be impressive as a dyno result, but the DFIC2 really shines with on-the-road airflow.

Optional Accessories Available:
• M7 Aerogel Heatshield--a MUST for maximum heat rejection
• M7 Ultimate DFIC Grille (Black or Silver)--designed specifically for the DFIC hood scoop


-- System with Original Brushed Aluminum: $899
-- System with Polished Mirror Finish: $974
-- System with Black Heat Dissipating Coating: $1,009 (shown in picture)


SYSTEM INCLUDES
-- Intercooler
-- Custom DFIC Hood Scoop
-- Silicone Intercooler Boots (choice of red or blue)
-- Intercooler Diverter (black powder coated or polished depending on intercooler finish)
-- Foam padding
-- Stainless Steel Hardware


Applications:
'02 - '06 MCS
M7 DFIC Aerogel Heatshield
Our Price: $99.00

Always trying to push the envelope with the latest technology available, M7 has created the M7 Aerogel Heatshield. Aerogel is nanotechnology with amazing heat rejection qualities, which is why NASA is also using this material in a variety of applications.

The M7 Aerogel Heatshield is a hybrid product that will both reflect IR emission and act as the best possible heat barrier. This custom made heatshield is specifically designed for the DFIC and will cover the area from the front of the plastic radiator shroud covering the radiator hose (which is a major source of heat) all the way to the edge of the sparkplug tubes. Side-to-side it will cover more than the width of the intercooler.

Nickel-plated grommets keep the heatshield securely in place. The top material is a woven composite that offers both heat rejection and abrasive resistance. The bottom material is the aluminized fiberglass blanket that is superior at reflecting IR emission, which also helps with the cooling effect.

M7 TESTING:
Control Surface: Aluminum surface heated to a final temp of 440° F.

Test Thermometer: Dwyer Instruments IR 450 non-contact thermometer.

M7 Aerogel Heatshield: After 5 minutes there were no appreciable changes in temperature at the upper surface. So we left the mat baking on the control surface for another 30 minutes. The results: 135° F on the top surface and 440° F on the bottom of the mat! Now that's heat rejection.

Note: The M7 Aerogel Heatshield does not work with the stock-style, top-mount intercoolers as it will prevent air from flowing through the core.


Applications:
'02 - '06 MCS (Must have DFIC or similar intercooler installed)
Madness New MINI Cooper S Water to Air Intercooler
Our Price: $1,549.00

Problems and Solutions

In the search for better cooling we have tried larger air to air intercoolers with little to no gain in HP. Bigger is not always better! The problem with larger air to air intercoolers for the MINI is this, airflow is limited by the small hood scoop size in the factory hood, compare the MINI Cooper hood scoop to the Subaru STI and you'll get the idea. Once air finally enters the hood scoop it is directed through the intercooler to remove heat that has been absorbed, the problem then becomes poor placement of the intercooler, it sits right on top of the valve cover, fuel rail, injectors and intake manifold. There simply isn't enough clean flowing space underneath the intercooler to provide proper airflow to remove heat from the intercooler. A good execution of this type of intercooler design is once again the Subaru WRX or STI where the intercooler is top mount but the difference it where it's placed, to the rear of the engine where there is plenty of space for incoming air to flow through the intercooler and escape through the empty space below.  

The bottom line is that the MINI suffers terrible HP loss from poor airflow over the intercooler and heat soak conditions from its poor placement atop the engine.  

Here's where the Madness Water to Air Intercooler differs.

Our unit uses a modified factory intercooler which ensures 0% pressure drop, trouble free fit, low cost and no interference with any other engine components.  Water flows in from the top and flows through the intercooler exiting at the bottom.   The coolant fluid then is pumped at high speed with our 8 gpm water pump into the front mount radiator.  At this point the water makes 3 passes through the radiator before it exits and returns back to the top of the intercooler.  Passing the water through the radiator 3 times ensures that most of the heat been removed allowing the cool water to enter the intercooler and reduces intake temperatures dramatically. Other kits on the market use poorly designed radiators to cool the water, some even use the Automatic transmission cooler from the standard MINI.  These radiators are simple cross flow designs, small and inefficient and meant to flow transmission fluid. When it comes to cooling the water flowing through the system they simply cannot cool the water fast enough and do not have the necessary volume to maintain cool temperatures under constant use.

Stability and Consistency

In repeated track testing our MINI Cooper Water to air intercooler maintained a 40 degree temperature difference vs ambient temperature.  These tests were performed on a Stage 4 modified MINI Cooper S running 5, 30minute track sessions.  Speeds in excess of 130mph were consistently reached with no increase from lap to lap as the day grew hotter.

Whats included

Double size 3 pass front mount radiator, Silicone 3 ply hoses, High flow 8gpm continuous run water pump, High polished Intercooler, overflow tank, and full color installation instructions

Additional options include a digital 3-way temperature gauge to monitor the intercooler temperature conditions. This gauge alows you to monitor inlet temperature, outlet temperature and the delta temperature which at a glance shows you how well the intercooler is diong it's job.

Performance

Final testing has shown a whopping 25 hp savings over the stock intercooler! 4 months of testing and prototyping have shown us that this solution provides the best cooling over a wide range of conditions from drag racing to street driving to the race track. Owners of our previous system can easily upgrade to the new kit by purchasing our upgrade kit.
MINI COOPER SERVICE MANUAL 2002-2006 (BENTLEY) COOPER AND S
Our Price: $110.00

The MINI Cooper Service Manual: 2002-2006 for Cooper and Cooper S including Convertibles is a comprehensive source of service information and specifications for MINI Cooper models from 2002 to 2006.

The aim throughout this manual has been simplicity, clarity and completeness, with practical explanations, step-by-step procedures and accurate specifications. Whether you're a professional or a do-it-yourself MINI owner, this manual will help you understand, care for and repair your car.

Though the do-it-yourself MINI owner will find this manual indispensable as a source of detailed maintenance and repair information, the owner who has no intention of working on his or her car will find that reading and owning this manual will make it possible to discuss repairs more intelligently with a professional technician.

Models and engines covered:
• Cooper: 1.6 liter normally aspirated engine
• Cooper S: 1.6 liter supercharged engine
• Hatchback and Convertibles

Transmissions covered:
• Cooper: Manual 5-speed transmission (Midlands, Getrag)
• Cooper: Automatic continuously variable transmission (CVT)
• Cooper S: Manual 6-speed transmission (Getrag)
• Cooper S: Automatic with Agitronic (Aisin)

Technical highlights:
• Procedures for everything from basic oil change service to interpreting the malfunction indicator light (MIL). This manual tells you what to do and how and when to do it.
• Engine and cylinder head service, including camshaft timing chain setup and adjustment.
• Information for specific driveability problems, including explanation of the engine management system and OBD II diagnostic trouble codes (DTCs)
• Theory of operation and repair information for the EMS2000 engine management system.
• Supercharger and intercooler information, including component removal and replacement (Cooper S)
• Drivetrain maintenance, including troubleshooting, adjustment and repair of clutch, gearshift linkage and drive axles.
• Manual and automatic transmission removal, installation, seal replacement and external service.
• System description and repair information for Antilock Brakes (ABS), Automatic Stability Control (ASC) and Dynamic Stability Control (DSC).
• Heating and air conditioning repair (IHKS / IHKA), including component replacement.
• Body adjustments and repairs, including sunroof and convertible.
• Wiring schematics and extensive electrical component section specifying relay, control module and ground locations with detailed illustrations and photos.
by Bentley Publishers
Softcover, 8 3/8 in. x 11 in.
1084 pages
1902 photos, illustrations and diagrams
CryO2 System
Our Price: $393.33

The foundation to every CryO2 System. Must have this kit to utilize CryO2 components. The kit includes a 10 pound CO2 tank, cryogenic solenoid valve, all necessary fittings, 14 ft. stainless steel hose, full wide open switch, arming switch and a wiring kit. Only one kit is needed to operate all the CryO2 components.
CryO2 Intercooler Sprayer R53
Our Price: $85.33

The CryO2 Intercooler Sprayer mounts directly to the front of the intercooler or aftercooler and vents the liquid CO2 directly onto the cooling fins, thus enhancing the performance of the intercooler by more than 50%. This component must always be the last in the CryO2 system as it vents the liquid CO2 charge.