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TKART magazine Special | New-Line Racing 2020 radiators, the complete guide
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Max Bernardi
20 May 2020
Cooling your engine properly is crucial to get the best performance out of it. The leading company in the manufacturing of radiators for karts knows it and, for the new 2020 product range, has introduced an innovative radiator core. Let's learn more about it and all other products in the catalog, to understand which radiator best suits the needs of your kart

New-Line Racing: the company

New-Line Racing is the leading manufacturer of radiators for karting. Its story dates back to 90s when the then driver Marco Malverti understood how important radiator efficiency was for the first water-cooled engines introduced in karting. The first prototypes were realised with the help of his two friends and Ferrari metalworkers, Alberto Frigeri and Massimo Benedetti, which soon triggered a surge in demand from other kart drivers and, in fact, marked the beginning of the history of New-Line Racing.
The history of the New-Line Racing begins with its product: the kart radiator. The first prototypes were realised around 1996-1997, to be used by the then driver Marco Malverti. The New-Line Racing brand didn’t exist yet, but, given the many requests that started immediately to come in from many kart drivers, in 1998 Malverti, together with his partners Frigeri and Benedetti, officially created the company. At the beginning, the production was of about 50 units per year. Today the annual output exceeds 8000 units, adding the radiators made for the first system for chassis manufacturers and the aftermarket products sold under the New-Line brand. An unstoppable growth constantly fueled by new manufacturing processes always aimed at increasing the quality of the products and cutting production times.
A glimpse inside New-Line Racing headquarters, in Maranello, where the radiators of the entire range are manufactured by hand by Frigeri and Benedetti.
The founding partners and still owners of New-Line Racing: from the left, Massimo Benedetti, Marco Malverti and Alberto Frigeri.
New-Line Racing radiators are 100% handcrafted products, handmade, one by one, and subjected to strict quality control tests. A single radiator requires from 4 to 6 hours of work, depending on the model. The choice of raw materials, which must be able to withstand high operating temperatures, are crucial to maintain a consistent product quality, together with the assembly stage, totally carried out in Italy a by specialized operators through manual welding.
Some close-ups of the weldings of New-Line Racing radiators, welded entirely by hand.
The water outlets, ready to be welded onto the radiators.
New-Line Racing focuses heavily on the constant development of its products. Research and innovation stems from drawings, prototypes and tests on the track, while, as for the development, the Italian company believes that the best insights come from in the highest-level competitions that take place all over the world, with the most successful and the most demanding drivers and technicians. For this reason, New-Line Racing partners with many official Racing Teams to which it provides full support in races in every continent. On the other hand, the parts that needs to be developed, even in a radiator, a product that might look simple at first, are many: the latest update focuses on the radiator core, now expressly made for karting requirements and capable to further improve the cooling capacity of the radiator (so far, the cores that have been used were meant for other automotive sectors).
CRG, Birel, Lennox Racing ... These are just a few of the most important teams that benefits from a close partnership with New-Line Racing.
The test bench allows to calculate the water pump flow rate and to assess the distribution of the water across the radiator, a key factor in determining its cooling efficiency.
A track test during which TKART had the chance to try horizontal radiator, another futuristic project realized by New-Line Racing in recent years.

New products together with tested-and-trusted ones

The New-Line Racing 2020 product range certainly doesn’t lack in novelties, with the main one being the introduction of the innovative MAX radiator core. But the research and development effort of the Italian company based in Maranello hasn’t sopped to radiators, as all the accessories and the components related to the cooling system have been revised. The ultimate goal is always to improve both performances and ease of use.
The revolutionary MAX radiator core characterizes the MAX radiator line which rounds out the New-Line Racing 2020 product range. The new core distinguishes itself for having a smaller gap between the tubes: compared to the standard core, this gap has gone from 8 to 6 mm. This allows, for a given area, a greater waterflow and, therefore, an increase in heat-exchange rate which turns into a more effective cooling. The fins are also new, whose folding is now less tight than before: a twenty-fin pitch now measures 30 mm, against the 25mm of the standard core. These new features led to an increase cooling capacity of the MAX core of up to 10%.
The thickness of the radiator is also reduced and went from 40 to 35 mm. An improvement that allowed a 20% decrease in weight compared to traditional radiators. This development leads to many technical implications that TKART will soon break down in a dedicated Tech Focus.
The standard radiators are still featured in the New-Line Racing catalogue, along with the new 2020 models, offering kart drivers a wider choice.
The products making up the Max line are also identified by a new logo.
Another important and innovative feature of New-Line Racing radiators, but that's not intended for all the models in the range, is the double pass cooling circuit. This configuration is obtained thanks to a baffle welded inside the top tank: this way, the water that flows in will go through only the innermost tubes of the radiator (namely, those closest to the driver). So, from the top tank, the water flows downwards through the innermost portion of the core for a first drop in temperature. Once in the bottom tank, the water goes up again through an external aluminum tube heading towards the second half of the radiator core for a second cooling cycle. At the end, the water is pushed towards the engine by the work of the water pump. This solution forces the water to stay inside the radiator for more time, thus improving cooling.
This drawing shows how the double pass works, with the radiator core divided into two parts
As mentioned, apart from radiators, New-Line Racing also offers a very wide range of accessories that improve their cooling capacity. The shield and the screen, for example, can be used to control the surface of the radiator core that gets exposed to airflow to decrease or increase cooling. The deflector, on the other hand, works as a turning vane to be mounted on the outermost side of the radiator that helps to channel fresh air towards the hot air coming out of the back of the radiator. A solution that helps the radiator work properly and shields the left rear tire of the kart from hot air, helping it keep its optimal pressure. The cap, billet machined, is fitted as standard in New-Line Racing radiators. It's set at 1.8 bar, which avoids unwanted water venting in the event of shocks or vibrations, as it can happen with lower pressure settings. The water recovery tank, small in size, is shaped in order to be easily fixed behind the radiator without obstructing the ouflow of hot air.
The shield has a dual functionality: when shut, it reduces the surface of the radiator core exposed to airflow, decreasing cooling. When opened up, it acts as a conveyor, improving cooling.
The screen is the handiest accessory for changing the engine cooling temperature. When unrolled it helps the engine reach the optimal operating temperature faster  Conversely, once rolled up, the cooling system works at full capacity.
The radiator cap is billet machined. The 1.8 bar pressure setting prevents venting in the event of shocks or vibrations. The vent pipe connector can rotate 360 degrees.
The water recovery tank, small in size in order not to obstruct the outflow of hot air, is available in different colors.
The supports are also worth mentioning, essential accessories for mounting the radiator at the proper angle. These accessories have been studied in detail and designed in order to reduce their weight as much as possible without compromising their stiffness. The silentblocks mounted between the supports and the radiator ensure that the vibrations coming from the track and the chassis get properly dampened. The brackets can be adjusted to tilt the radiator: usually the correct position is between 55 ° and 60° with respect to horizontal, depending on the air temperature.
The new supports are hollowed out to reduce their weight.
New-Line Racing supports are available in red, blue, black, gold, orange and aluminum colors.
The more the radiator is vertical, the greater the airflow that hits the radiator core. It is recommended, however, to opt for an angle ranging between 55 ° to 60 ° with respect to the horizontal.
As for the cooling system as a whole, apart from the radiator, the list of the 2020 novelties sees also the introduction of the new silicone hose that goes from the pump to the engine, with pre-formed bends as standard so as to alter the flow rate of the water as less as possible.
Another fundamental component of the cooling system is the water pump: driven by the axle via OR or toothed belt, it is completely billet machined in order to maximize reliability and performance.
Both the pump casing and the impeller of the water pump are billet machined.
The New-Line Racing silicone hoses with pre-formed bends. They are available in different colors.


Now that we have overviewed the general features and the new products, it's time to try to answer the question that arises in every kart driver's mind when buying a new radiator: which model is right for my kart? And how do you navigate your way through such a vast choice when looking for what fits your needs? Let's break it down.
The New-Line Racing 2020 range covers all the engine cooling needs, both for single-speed engines and for shifter configurations. The engines in the first category operate at lower temperatures than those equipped with a gearbox, enabling smaller radiators, which cause less aerodynamic drag and are also lighter. On the contrary, KZ engines need more cooling and, therefore, larger radiators. The New-Line Racing offer, however, does not differ only in terms of size: some models have a double-pass internal cooling circuit, designed to increase the heat exchanged between water and air. This solution improves cooling but also dissipates more power to maintain the desired flow of water, thus making them less suitable for single-speed engines, which are less powerful than shifter engines.
The screen serves the purpose of controlling how much of the surface of the radiator core gets exposed to airflow.
In the photo you can notice the curved shape of the inlet of the top tank, a design that improves the distribution of the water across the entire radiator core.
Air temperature is one of the main factors that affects engine cooling requirements: the New-Line Racing range takes into account all situations and provides the optimal solution for any time of the year. If you go karting when temperatures are below 20 degrees Celsius, for example, what you need is a small radiator. But the same radiator will fall short when temperatures rise above 30 degrees. Having an idea of what the air temperature will be when you take to the track is crucial in choosing the correct radiator.
As a rule of thumb, a larger radiator is useful in the event of warmer temperatures.
Smaller radiators might be more suitable for single-speed engines, less powerful than those used in KZ.
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