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09-19-07, 06:10 PM
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 #1 (permalink)
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Lifer with a 2F-ETI
Join Date: Jan 2006
Location: Melbourne
Posts: 2,099
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Home Brew Intercooler
This is posted in the 40's section but I though I would re-post it here too as it may be of more use.
__________________
If the wife's not complaining your not spending enought time with your 40!
2F+3FE+T+I-3F=2F-ETI
THE MULE Est @ +400hp @ 15PSI
DYNO'd at 8PSI 181kw/244hp & 560Nm/413ftlb @ the RW 8th Dec 08
EST @ FLY 283KW/379HP
Links
Mac's Space 
On the rev limiter 
Advanced (HB) Intercoolers
Last edited by matt.mcinnes; 12-06-08 at 02:09 AM.
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09-19-07, 10:31 PM
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#2 (permalink)
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250+ Club
Join Date: Aug 2005
Location: Abbotsford B.C.
Posts: 646
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Some nice work there.
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09-20-07, 12:38 AM
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#3 (permalink)
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Site Addict
Join Date: Jun 2007
Location: Being stalked by 2 hillbillies
Posts: 2,034
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Very nice handiwork there.
When you get it done, have you got enough instrumentation to work out how much heat it's pulling out?
__________________
VOODOO Engineering: Doing it first time with one clay doll, not four times with two.
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09-20-07, 01:54 AM
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#4 (permalink)
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Lifer with a 2F-ETI
Join Date: Jan 2006
Location: Melbourne
Posts: 2,099
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Quote:
Originally Posted by Dougal
Very nice handiwork there.
When you get it done, have you got enough instrumentation to work out how much heat it's pulling out?
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The Wolf V500 can and will monitor the air temp after the intercooler in the plenium , I have access too a laser temp sensor too. Though I am tempted to get an air temp sensor on the input just to see if this home brew kit works and if so how well the ECU can handle it no problem.
Some numbers would be interesting for sure.
Just have to figure out what radiator and thermo fan to use along with an electric pump.
__________________
If the wife's not complaining your not spending enought time with your 40!
2F+3FE+T+I-3F=2F-ETI
THE MULE Est @ +400hp @ 15PSI
DYNO'd at 8PSI 181kw/244hp & 560Nm/413ftlb @ the RW 8th Dec 08
EST @ FLY 283KW/379HP
Links
Mac's Space
On the rev limiter
Advanced (HB) Intercoolers
Last edited by matt.mcinnes; 09-20-07 at 02:07 AM.
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09-20-07, 03:56 AM
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#5 (permalink)
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Site Addict
Join Date: Jun 2007
Location: Being stalked by 2 hillbillies
Posts: 2,034
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Quote:
Originally Posted by matt.mcinnes
Just have to figure out what radiator and thermo fan to use along with an electric pump.
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Since you're in Aussie, the subaru air/water intercooler pumps shouldn't be too hard to find. I've got one and they are ideal, pull about 5 amps at full load.
I'm using a cabin heater radiator. It does the job, find one from a bus cabin heater if you feel the need for something bigger.
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VOODOO Engineering: Doing it first time with one clay doll, not four times with two.
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09-20-07, 01:49 PM
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#6 (permalink)
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Turbo Diesel Lover
Join Date: Apr 2003
Location: Panamá
Posts: 11,423
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Intercoolers @ 14PSI can drop ( properly suited ) about 50ºC - 60ºC at HW speed ( talking about air to air ) how much you expect on you . ?
BTW it's a nice job !
__________________
HJ-60 2H-T Intercooled Tencha
HDJ-80 1HD-T not stock at all ! Marilu
FZJ-80 1FZ-FE ready to Play ( wife rig ! )
Join us at our local Panamá Off Road Forum
Quote:
Originally Posted by crushers
if you are achieveing the max boost then it isn't the boost that is going to kill your engine... it is your right foot.
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09-20-07, 02:38 PM
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#7 (permalink)
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Lifer with a 2F-ETI
Join Date: Jan 2006
Location: Melbourne
Posts: 2,099
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Quote:
Originally Posted by Tapage
Intercoolers @ 14PSI can drop ( properly suited ) about 50ºC - 60ºC at HW speed ( talking about air to air ) how much you expect on you . ?
BTW it's a nice job !
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I have no idea, the math that goes into calcultaing these thing is way over my head 
One thing I do know is at comp highway speeds are never achived, I was quoted $3000Aus buy a company here in Melbourne that use these cores, for a custom made intercooler using 3 cores (they said that would be sufficient to my needs). I bought 4 on ebay and what the hell used all of them for $50Aus
So making a home brew intercooler with little understanding of heat transfer rates and the math that goes into them is a bit of a punt.
On the other side of the coin if it works it will have been very rewarding to do it myself and save a fortune.
Proof for me will be in the pudding
__________________
If the wife's not complaining your not spending enought time with your 40!
2F+3FE+T+I-3F=2F-ETI
THE MULE Est @ +400hp @ 15PSI
DYNO'd at 8PSI 181kw/244hp & 560Nm/413ftlb @ the RW 8th Dec 08
EST @ FLY 283KW/379HP
Links
Mac's Space
On the rev limiter
Advanced (HB) Intercoolers
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09-20-07, 03:14 PM
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#8 (permalink)
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Turbo Diesel Lover
Join Date: Apr 2003
Location: Panamá
Posts: 11,423
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Quote:
Originally Posted by matt.mcinnes
I bought 4 on ebay and what the hell used all of them for $50Aus |
And I thought gent a nice deal with mine .. 
__________________
HJ-60 2H-T Intercooled Tencha
HDJ-80 1HD-T not stock at all ! Marilu
FZJ-80 1FZ-FE ready to Play ( wife rig ! )
Join us at our local Panamá Off Road Forum
Quote:
Originally Posted by crushers
if you are achieveing the max boost then it isn't the boost that is going to kill your engine... it is your right foot.
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09-20-07, 04:04 PM
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#9 (permalink)
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Lifer with a 2F-ETI
Join Date: Jan 2006
Location: Melbourne
Posts: 2,099
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Quote:
Originally Posted by Tapage
And I thought gent a nice deal with mine .. |
I have emailed the R&D department at Laminova with a link to the thread for their comment, they may or may not care to comment but you can always ask the experts.
Quote:
Hi Mattias,
I was wondering if you would care to comment on my use of your Laminova intercooler cores. You may even find it of interest. Any suggestion of how well this will or will not work will be more than welcome.
http://forum.ih8mud.com/showthread.p...light=laminova
Thankyou for taking the time if you do so.
Regards Matt McInnes
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__________________
If the wife's not complaining your not spending enought time with your 40!
2F+3FE+T+I-3F=2F-ETI
THE MULE Est @ +400hp @ 15PSI
DYNO'd at 8PSI 181kw/244hp & 560Nm/413ftlb @ the RW 8th Dec 08
EST @ FLY 283KW/379HP
Links
Mac's Space
On the rev limiter
Advanced (HB) Intercoolers
Last edited by matt.mcinnes; 09-20-07 at 04:51 PM.
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09-20-07, 10:12 PM
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#10 (permalink)
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250+ Club
Join Date: May 2006
Location: Oregon Coast
Posts: 271
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fawk yeah! Do you just run the engine coolant lines or do you need another reservoir? How does that work?
__________________
PORTLANDERS + NW CRUISERS::
$@#!! L A N D C R U I S E R S P E C I A L T I E S !!!
H O R R I B L E W O R K , W O R S E A C C O U N T A B I L I T Y!!! 
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09-20-07, 10:19 PM
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#11 (permalink)
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Forum Regular
Join Date: Aug 2006
Posts: 98
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very very technical and nice mechanical job, and very interesting for me, in italy water intercooler are not used yet.
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09-21-07, 09:31 AM
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#12 (permalink)
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Turbo Diesel Lover
Join Date: Apr 2003
Location: Panamá
Posts: 11,423
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Quote:
Originally Posted by matt.mcinnes
I have emailed the R&D department at Laminova with a link to the thread for their comment, they may or may not care to comment but you can always ask the experts. |
Thanks .. !
__________________
HJ-60 2H-T Intercooled Tencha
HDJ-80 1HD-T not stock at all ! Marilu
FZJ-80 1FZ-FE ready to Play ( wife rig ! )
Join us at our local Panamá Off Road Forum
Quote:
Originally Posted by crushers
if you are achieveing the max boost then it isn't the boost that is going to kill your engine... it is your right foot.
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09-22-07, 07:14 AM
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#13 (permalink)
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Urban Offroader
Join Date: Nov 2006
Location: Dexter Michigan
Posts: 451
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so basically you have a seperate cooling system from the charge air cooler? With a small radiator in front of the main radiator? I am intrested to see the temp drop, pre and post intercooler. How did you cut your metal so good? Post some pics of the tools you used.
good work!
__________________
1991 T4R 5sp.
1988 FJ62
1999 Jeep Wrangler
I want an FZJ80 with minimal mall cruiser stuff, and F+R diff locks. Can trade jeep+cash, or just cash. Prefer OBD1.
Please i despertly need to get my 1FZ fix.
Never mind, I got an RX7 to play with this summer.
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09-24-07, 04:30 AM
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#14 (permalink)
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Lifer with a 2F-ETI
Join Date: Jan 2006
Location: Melbourne
Posts: 2,099
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Quote:
Originally Posted by PurpleFJ62
so basically you have a seperate cooling system from the charge air cooler? With a small radiator in front of the main radiator? I am intrested to see the temp drop, pre and post intercooler. How did you cut your metal so good? Post some pics of the tools you used.
good work!
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Used a lath and a milling machine to make the parts, but it could be done with more basic tools and ingenuity. Eg hole saw
Small radiator and thermo fan will be used as I want this to work at low speeds and an electric pump. May even be mounted in the rear out of the way of the mud.
__________________
If the wife's not complaining your not spending enought time with your 40!
2F+3FE+T+I-3F=2F-ETI
THE MULE Est @ +400hp @ 15PSI
DYNO'd at 8PSI 181kw/244hp & 560Nm/413ftlb @ the RW 8th Dec 08
EST @ FLY 283KW/379HP
Links
Mac's Space
On the rev limiter
Advanced (HB) Intercoolers
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09-24-07, 01:05 PM
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#15 (permalink)
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Lifer with a 2F-ETI
Join Date: Jan 2006
Location: Melbourne
Posts: 2,099
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Quote:
Originally Posted by Tapage
Thanks .. !
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No Problem
__________________
If the wife's not complaining your not spending enought time with your 40!
2F+3FE+T+I-3F=2F-ETI
THE MULE Est @ +400hp @ 15PSI
DYNO'd at 8PSI 181kw/244hp & 560Nm/413ftlb @ the RW 8th Dec 08
EST @ FLY 283KW/379HP
Links
Mac's Space
On the rev limiter
Advanced (HB) Intercoolers
Last edited by matt.mcinnes; 12-06-08 at 02:37 AM.
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09-24-07, 06:58 PM
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#16 (permalink)
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Site Addict
Join Date: Jun 2007
Location: Being stalked by 2 hillbillies
Posts: 2,034
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80L/min!
That's a whole lot of water. I guess that rules out the subaru pump. Maybe the Davies one?
__________________
VOODOO Engineering: Doing it first time with one clay doll, not four times with two.
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09-24-07, 07:36 PM
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#17 (permalink)
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Lifer with a 2F-ETI
Join Date: Jan 2006
Location: Melbourne
Posts: 2,099
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Yep I was looking at the 110 model should give plenty for my needs.
__________________
If the wife's not complaining your not spending enought time with your 40!
2F+3FE+T+I-3F=2F-ETI
THE MULE Est @ +400hp @ 15PSI
DYNO'd at 8PSI 181kw/244hp & 560Nm/413ftlb @ the RW 8th Dec 08
EST @ FLY 283KW/379HP
Links
Mac's Space
On the rev limiter
Advanced (HB) Intercoolers
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09-24-07, 08:22 PM
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#18 (permalink)
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Forum Lifer
Join Date: Sep 2002
Location: Vancouver Island BC Canada
Posts: 4,649
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How about the little bosch water pump?
Really interesting thread, great looking work.
__________________
Come and visit us in Duncan, Vancouver Island, BC
www.raddcruisers.ca
Monday - Friday 08:00 - 17:00
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09-24-07, 10:23 PM
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#19 (permalink)
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Lifer with a 2F-ETI
Join Date: Jan 2006
Location: Melbourne
Posts: 2,099
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Quote:
Originally Posted by Radd Cruisers
How about the little bosch water pump?
Really interesting thread, great looking work.
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You have a link or part number?
__________________
If the wife's not complaining your not spending enought time with your 40!
2F+3FE+T+I-3F=2F-ETI
THE MULE Est @ +400hp @ 15PSI
DYNO'd at 8PSI 181kw/244hp & 560Nm/413ftlb @ the RW 8th Dec 08
EST @ FLY 283KW/379HP
Links
Mac's Space
On the rev limiter
Advanced (HB) Intercoolers
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09-25-07, 09:03 AM
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#20 (permalink)
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Forum Lifer
Join Date: Sep 2002
Location: Vancouver Island BC Canada
Posts: 4,649
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Quote:
Originally Posted by matt.mcinnes
You have a link or part number?
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http://images.google.ca/imgres?imgur...%3Den%26sa%3DN
One of the reasons I like bosch also is they offer a 24volt pump.
What do you think the weight is going to be including coolant?
Not sure if this will work, never added a link before.
__________________
Come and visit us in Duncan, Vancouver Island, BC
www.raddcruisers.ca
Monday - Friday 08:00 - 17:00
Last edited by Radd Cruisers; 09-25-07 at 09:08 AM.
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09-25-07, 09:42 AM
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#21 (permalink)
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Lifer with a 2F-ETI
Join Date: Jan 2006
Location: Melbourne
Posts: 2,099
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Quote:
Originally Posted by Radd Cruisers
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Thanks for the link works fine, I have a few friends that work at Bocsh so I maybe able to get it much cheaper if it's available.
Final weight I have no idea but once finished I can weigh it up, though weight is not a great issue over sturdy construction for competition.
__________________
If the wife's not complaining your not spending enought time with your 40!
2F+3FE+T+I-3F=2F-ETI
THE MULE Est @ +400hp @ 15PSI
DYNO'd at 8PSI 181kw/244hp & 560Nm/413ftlb @ the RW 8th Dec 08
EST @ FLY 283KW/379HP
Links
Mac's Space
On the rev limiter
Advanced (HB) Intercoolers
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09-26-07, 06:02 PM
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#22 (permalink)
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Lifer with a 2F-ETI
Join Date: Jan 2006
Location: Melbourne
Posts: 2,099
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Dropped the sleeves, end plates and divider in to the welders today. Cash job The guy that does the welding is top notch with a tig. But as a job on the side I have to be patient, 2 weeks.
While this is done all the end caps can be machined up, once we get the newly welded up section back the holes to mount the end caps can then be drilled in the end plates before the final outer skin os welded over.
__________________
If the wife's not complaining your not spending enought time with your 40!
2F+3FE+T+I-3F=2F-ETI
THE MULE Est @ +400hp @ 15PSI
DYNO'd at 8PSI 181kw/244hp & 560Nm/413ftlb @ the RW 8th Dec 08
EST @ FLY 283KW/379HP
Links
Mac's Space
On the rev limiter
Advanced (HB) Intercoolers
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09-28-07, 03:03 AM
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#23 (permalink)
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Forum Regular
Join Date: Aug 2007
Posts: 50
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i have a hzj75 ute and i am going to mount my cooler core in the centre of the bullbar, horizontally. open the flat bit and put mesh above core or maybe flute the top of the bar to direct air in, thermo also underneath...out of harms way
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10-06-07, 12:03 AM
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#24 (permalink)
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Lifer with a 2F-ETI
Join Date: Jan 2006
Location: Melbourne
Posts: 2,099
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All welded up thanks to Awill4x4 and as always top quality work.
Now on with the end caps
__________________
If the wife's not complaining your not spending enought time with your 40!
2F+3FE+T+I-3F=2F-ETI
THE MULE Est @ +400hp @ 15PSI
DYNO'd at 8PSI 181kw/244hp & 560Nm/413ftlb @ the RW 8th Dec 08
EST @ FLY 283KW/379HP
Links
Mac's Space
On the rev limiter
Advanced (HB) Intercoolers
Last edited by matt.mcinnes; 10-06-07 at 12:53 AM.
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10-24-07, 07:00 PM
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#25 (permalink)
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Lifer with a 2F-ETI
Join Date: Jan 2006
Location: Melbourne
Posts: 2,099
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End caps are complete
3/4 assembled
Pressure tested and all good 
Next the outer skin is to be welded on, along with the inlet and outlet.
__________________
If the wife's not complaining your not spending enought time with your 40!
2F+3FE+T+I-3F=2F-ETI
THE MULE Est @ +400hp @ 15PSI
DYNO'd at 8PSI 181kw/244hp & 560Nm/413ftlb @ the RW 8th Dec 08
EST @ FLY 283KW/379HP
Links
Mac's Space
On the rev limiter
Advanced (HB) Intercoolers
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10-31-07, 03:54 PM
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#26 (permalink)
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Lifer with a 2F-ETI
Join Date: Jan 2006
Location: Melbourne
Posts: 2,099
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__________________
If the wife's not complaining your not spending enought time with your 40!
2F+3FE+T+I-3F=2F-ETI
THE MULE Est @ +400hp @ 15PSI
DYNO'd at 8PSI 181kw/244hp & 560Nm/413ftlb @ the RW 8th Dec 08
EST @ FLY 283KW/379HP
Links
Mac's Space
On the rev limiter
Advanced (HB) Intercoolers
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10-31-07, 04:05 PM
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#27 (permalink)
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Forum Lifer
Join Date: Feb 2004
Posts: 11,933
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pretty damn cool if you ask me...
thanks for posting...
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11-01-07, 11:25 PM
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#28 (permalink)
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Lifer with a 2F-ETI
Join Date: Jan 2006
Location: Melbourne
Posts: 2,099
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Will be dropping it at the welders next Wednesday morning
__________________
If the wife's not complaining your not spending enought time with your 40!
2F+3FE+T+I-3F=2F-ETI
THE MULE Est @ +400hp @ 15PSI
DYNO'd at 8PSI 181kw/244hp & 560Nm/413ftlb @ the RW 8th Dec 08
EST @ FLY 283KW/379HP
Links
Mac's Space
On the rev limiter
Advanced (HB) Intercoolers
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11-02-07, 01:41 AM
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#29 (permalink)
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Forum Lifer
Join Date: Feb 2004
Posts: 11,933
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looking forward to the fitment...
cheers
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11-09-07, 08:30 PM
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#30 (permalink)
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Lifer with a 2F-ETI
Join Date: Jan 2006
Location: Melbourne
Posts: 2,099
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__________________
If the wife's not complaining your not spending enought time with your 40!
2F+3FE+T+I-3F=2F-ETI
THE MULE Est @ +400hp @ 15PSI
DYNO'd at 8PSI 181kw/244hp & 560Nm/413ftlb @ the RW 8th Dec 08
EST @ FLY 283KW/379HP
Links
Mac's Space
On the rev limiter
Advanced (HB) Intercoolers
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matt.mcinnes
