12H-T intercooler install

The Dude · 03-09-08, 12:00 PM

Intercooler going in. It's a bit of a pain, I will need to relocate some AC lines and I am going to buy a new, long and skinny transmission cooler to go just above the intercooler. It's not bolted up yet, but it is getting close.

From the turbo. Not much clearance on this side with the alt and AC lines.

Piping coming out the front:

intercooler in:

bottom valance on:

grill back on:

the down pipe my buddy Kieth made for me. the piping fits inside so we can tig it from there and still have room for the bolts. It is beveled on the inside to go ftom the 2" ID stock flange to the 2.5" OD piping.

Dougal · 03-09-08, 01:54 PM

Very nice. Did you have "before" EGT measurements to compare when you're done?

The Dude · 03-09-08, 02:24 PM

You betcha. I even got an IR temp gauge so that I can get the before and after the intercooler numbers.

Dougal · 03-09-08, 02:28 PM

Quote:

Originally Posted by The Dude

You betcha. I even got an IR temp gauge so that I can get the before and after the intercooler numbers.

Nice.
A guy on outerlimits took a photo of his intercooler with a thermal imaging camera, that was really impressive.

lynchmob · 03-09-08, 02:36 PM

Looks good. Did you get that IC on ebay?

The Dude · 03-09-08, 02:42 PM

Yup, that was a cheapo for $55. The hose/clamps/piping was another $200

I figure it was worth a shot

lynchmob · 03-09-08, 02:46 PM

Do you have a link to the one you bought? Looks like a good fit in the 60. I know there is at least one company that lists what seems like hundreds of them.

Thanks

The Dude · 03-09-08, 02:53 PM

eBay Motors: CXRacing INTERCOOLER INTEGRA CIVIC CRX DEL SOL ACCORD (item 250222504329 end time Mar-12-08 15:30:00 PDT)

That is the one I got but it was on sale for $55. I then gave them a grocery list of what I needed for pipes and what not.

It is a tight fit. I needed to hog out the back side of my grill and lose the support for the hood latch. It woulld be MUCH nicer without the AC rad. You would have lots of room to work with. My square headlights also restricted access to the inside of the truck. Having round lights would give you more options on the width.

I would have considered going taller, but I believe the tranny cooler is a must have out front.

Talos · 03-09-08, 04:55 PM

looking good

Tapage · 03-10-08, 06:15 PM

Brad .. nice setup.

Just a note .. you plan allow your intercooler support all the weight and forces that produce the hood lock ?

The Dude · 03-10-08, 06:19 PM

Nope, if you look at the third picture down, I have a set of hood pins that hold the weight of the hood. The latch is just there safety reason now as you need to have a two stage latching system to run on the streets here in SK. The hood pins being my primary and the latch being the second.

Radd Cruisers · 03-11-08, 08:36 AM

Nice work as always DUDE, your threads are fun to follow.

rapovt · 03-11-08, 01:01 PM

How did you decide on the size for the intercooler? Is there any science involved or was it a "it looks good and the price is right" decision? I am going to find one for my 1hz

The Dude · 03-11-08, 02:18 PM

It took these numbers and divided by 2 as there is no intake on the combustion stroke (thanks 83bj60)

600 cfm flow rate is 16990L/min

4L engine at 2500rpms is 10000L per minute/2 is 5000L/min

With a .5 drop at 15psi (according to the intercooler specs)

It sounds OK to me. I guess the bigger you go the better cooling you could have. You will also suffer from greater turbo lag the bigger you go. Not a concern for me.

Tapage · 03-11-08, 04:22 PM

Quote:

Originally Posted by The Dude

It sounds OK to me. I guess the bigger you go the better cooling you could have.

That's it .. happy medium that place you in between good cooling capabilities and reasonable turbo lag

JoeCanadian · 03-12-08, 10:01 PM

looks highend to me, good job man

BURGER · 03-16-08, 11:42 PM

So how are things working out on this?? Pics??? Numbers??

The Dude · 03-17-08, 08:32 AM

Well, like all projects that initial look simple, when you actually get right down to it and start tightening things back up, I ran into a few problems.

The intercooler has to sit about an inch lower then in the previous pictures. That means that I had to cut the lower valance and repaint. I also needed to cut out the back of the grill a lot more then I thought. I also had to repaint my holes that I cut through the body.

I am also awaiting two more 45* silicon elbows.

My other issues was my tranny cooler. It was to be mounted above the intercooler but didn't fit. I had to search out a much smaller cooler and reinstall. I also ended up installing a PS cooler in front as well for my hydro assist.

While I was at it I decided to black out the grill and headlight trim. That meant blasting and painting all the plastic trim. I also went black on the intercooler so that it doesn't stand out.

It's coming along. I will get some new pictures up tonight.

The Dude · 03-17-08, 10:58 AM

I hope engine cooling won't be an issue...

Not sure what I am going to do about that if it is.

The Toyota is going to go body color and I will reinstall the red diesel trim piece.

Tapage · 03-17-08, 01:15 PM

Sure if you life here it would be a issue .. but there I don't think so. Loking good !

BURGER · 03-23-08, 01:18 AM

Did the piping you buy from just intercoolers come with the ends beaded or rolled to stop the silicone couplings and elbows from blowing off. Does it need to have these beaded and/or rolled edges

Also does anyone know what the hump couplings are for? I found a site that say its to build a high pressure intake? Not sure what that means though. Is it the side from the turbo to the intercooler or is it the side from the intercooler to the intake? Why do no other silicone parts come with the hump.

I've said hump way too many times...gotta go now

Cañonero · 03-23-08, 05:01 PM

Haven't you considered this option:

[IMG] http://img182.imageshack.us/my.php?image=hdj55cv0.jpg [/IMG]
[IMG] http://img401.imageshack.us/my.php?image=hdj56aa0.jpg [/IMG]
[IMG] http://img257.imageshack.us/my.php?image=hdj57rn8.jpg [/IMG]

BURGER · 03-24-08, 12:07 AM

Quote:

Originally Posted by Cañonero

Haven't you considered this option:

[IMG] http://img182.imageshack.us/my.php?image=hdj55cv0.jpg [/IMG]
[IMG] http://img401.imageshack.us/my.php?image=hdj56aa0.jpg [/IMG]
[IMG] http://img257.imageshack.us/my.php?image=hdj57rn8.jpg [/IMG]

I have the feeling that there would be huge losses in the form of heat soak. Under the hood temps for my hj are high and I think you would get better gains with a front mounted IC. Plus I think the scoop is only marginally moving enough air over the IC to really make a difference.Less surface area on the scoop opening plus having to make a 90 degree turn equals less gains

Cañonero · 03-24-08, 06:25 AM

Yes, I've heard about that problems of the top mounted intercooler.

The thing is I have the chance of getting the whole top mounted kit, including the bonnet vent, for a very low price, and it would be much costly to get the front mount kit.

I have clear that the front mount is a better option, but, what about fitting the top mount one and a big fan under it?

Would it work?

The Dude · 03-24-08, 07:18 PM

Quote:

Originally Posted by BURGER

Did the piping you buy from just intercoolers come with the ends beaded or rolled to stop the silicone couplings and elbows from blowing off. Does it need to have these beaded and/or rolled edges

Also does anyone know what the hump couplings are for? I found a site that say its to build a high pressure intake? Not sure what that means though. Is it the side from the turbo to the intercooler or is it the side from the intercooler to the intake? Why do no other silicone parts come with the hump.

I've said hump way too many times...gotta go now

The 90s ans straight pieces came with the beaded roll. I ended up having to cut a few of them off to shorten the pipes. I roughed up the ends with 60 grit sand paper to get a secure fit. I am sure this will be OK at moderate boost level (under 20psi)

I have never seen those hump couplings. Interesting... I think it might be a gimmick.

you can see the rolled ends in this pic:

panoramic · 04-02-08, 01:22 AM

Any status update?
If this works well, I might try to duplicate it on my FJ40/12HT....

The Dude · 04-02-08, 08:13 AM

It should be rolling tonight or tomorrow night for sure!

The Dude · 04-02-08, 03:57 PM

WOOHOO I could only do a short run as I ran into some coolant leaks. The truck was up to normal operating temps and I had two WOT runs hitting 1200* max on the EGT. I can't say if the EGTs are down yet as I didn't have it out long enough. I did noticed increased turbo lag of a second or two. No lost boost that I can tell.

On the hot side, I was getting readings of 90-100F right at the turbo and 86-88F on the hot side of the intercooler

On the cold side I was 64-66F at the intercooler and 58-60F right at the intake.

Tapage · 04-02-08, 05:01 PM

Very impresive the efect of this core .. 20º les it's nice !

03-09-08, 12:00 PM	#1
The Dude IH8MUD Addict Join Date: Jun 2003 Location: Saskatoon, SK TLCA# 8113 Posts: 911	12H-T intercooler install Intercooler going in. It's a bit of a pain, I will need to relocate some AC lines and I am going to buy a new, long and skinny transmission cooler to go just above the intercooler. It's not bolted up yet, but it is getting close. From the turbo. Not much clearance on this side with the alt and AC lines. Piping coming out the front: intercooler in: bottom valance on: grill back on: the down pipe my buddy Kieth made for me. the piping fits inside so we can tig it from there and still have room for the bolts. It is beveled on the inside to go ftom the 2" ID stock flange to the 2.5" OD piping. __________________ Brad T 88 HJ61 "Marmaduke " 12H-T, A440, extreme valve body, PI, cable lockers, PTO winch, SOA, 2" body lift, FF, ARP studs, Longfields, 5.29s, 38x14.5R16 Toyo MTs... 78 BJ 40/42/60

03-09-08, 01:54 PM	#2
Dougal IH8MUD Lifer Join Date: Jun 2007 Location: Being stalked by 2 hillbillies Posts: 1,481	Very nice. Did you have "before" EGT measurements to compare when you're done? __________________ VOODOO Engineering: Doing it first time with one clay doll, not four times with two.

03-09-08, 02:24 PM	#3
The Dude IH8MUD Addict Join Date: Jun 2003 Location: Saskatoon, SK TLCA# 8113 Posts: 911	You betcha. I even got an IR temp gauge so that I can get the before and after the intercooler numbers. __________________ Brad T 88 HJ61 "Marmaduke " 12H-T, A440, extreme valve body, PI, cable lockers, PTO winch, SOA, 2" body lift, FF, ARP studs, Longfields, 5.29s, 38x14.5R16 Toyo MTs... 78 BJ 40/42/60

03-09-08, 02:42 PM	#6
The Dude IH8MUD Addict Join Date: Jun 2003 Location: Saskatoon, SK TLCA# 8113 Posts: 911	Yup, that was a cheapo for $55. The hose/clamps/piping was another $200 I figure it was worth a shot __________________ Brad T 88 HJ61 "Marmaduke " 12H-T, A440, extreme valve body, PI, cable lockers, PTO winch, SOA, 2" body lift, FF, ARP studs, Longfields, 5.29s, 38x14.5R16 Toyo MTs... 78 BJ 40/42/60

03-09-08, 02:53 PM	#8
The Dude IH8MUD Addict Join Date: Jun 2003 Location: Saskatoon, SK TLCA# 8113 Posts: 911	eBay Motors: CXRacing INTERCOOLER INTEGRA CIVIC CRX DEL SOL ACCORD (item 250222504329 end time Mar-12-08 15:30:00 PDT) That is the one I got but it was on sale for $55. I then gave them a grocery list of what I needed for pipes and what not. It is a tight fit. I needed to hog out the back side of my grill and lose the support for the hood latch. It woulld be MUCH nicer without the AC rad. You would have lots of room to work with. My square headlights also restricted access to the inside of the truck. Having round lights would give you more options on the width. I would have considered going taller, but I believe the tranny cooler is a must have out front. __________________ Brad T 88 HJ61 "Marmaduke " 12H-T, A440, extreme valve body, PI, cable lockers, PTO winch, SOA, 2" body lift, FF, ARP studs, Longfields, 5.29s, 38x14.5R16 Toyo MTs... 78 BJ 40/42/60

03-09-08, 02:36 PM	#5
lynchmob Diesel Trucker Join Date: Mar 2007 Location: Portland OR - USA Posts: 1,009	Looks good. Did you get that IC on ebay?

03-09-08, 02:46 PM	#7
lynchmob Diesel Trucker Join Date: Mar 2007 Location: Portland OR - USA Posts: 1,009	Do you have a link to the one you bought? Looks like a good fit in the 60. I know there is at least one company that lists what seems like hundreds of them. Thanks

03-09-08, 04:55 PM	#9
Talos IH8MUD Regular Join Date: Jan 2006 Location: Iceland Posts: 240	looking good __________________ -1971 Toyota FJ-55 44" 302 etc. -1993 Toyota Carina E 2,0 GLi -1987 Toyota HJ-61 38" 12H-T http://forum.ih8mud.com/60-series-wagons/134457-hj-61-project-pics-ahoy.html Hj-61 intercooler: http://forum.ih8mud.com/diesel-tech-24-volts-systems/181830-hj-61-intercooling-thread.html

03-10-08, 06:19 PM	#11
The Dude IH8MUD Addict Join Date: Jun 2003 Location: Saskatoon, SK TLCA# 8113 Posts: 911	Nope, if you look at the third picture down, I have a set of hood pins that hold the weight of the hood. The latch is just there safety reason now as you need to have a two stage latching system to run on the streets here in SK. The hood pins being my primary and the latch being the second. __________________ Brad T 88 HJ61 "Marmaduke " 12H-T, A440, extreme valve body, PI, cable lockers, PTO winch, SOA, 2" body lift, FF, ARP studs, Longfields, 5.29s, 38x14.5R16 Toyo MTs... 78 BJ 40/42/60

03-11-08, 08:36 AM	#12
Radd Cruisers IH8MUD Lifer Join Date: Sep 2002 Location: Vancouver Island BC Canada Posts: 3,831	Nice work as always DUDE, your threads are fun to follow. __________________ Come and visit us in Duncan, BC www.raddcruisers.ca --> 60 Series Cable Lockers available - 4.11s or 3.70s - handles and cables included --> 12HT & H55F combos available - complete & running --> in stock and ready to go.

03-11-08, 01:01 PM	#13
rapovt IH8MUD Addict Join Date: Jan 2004 Location: Chester,vt. TLCA# 14086 Posts: 682	How did you decide on the size for the intercooler? Is there any science involved or was it a "it looks good and the price is right" decision? I am going to find one for my 1hz __________________ 1975 FJ40 2H/H55 1975 FJ40 Lifted,locked,toyboxed,woods rig 1971 PIG 1HZ,H55,60 axles(in Progress) 1980 HJ47 Troopy

03-11-08, 02:18 PM	#14
The Dude IH8MUD Addict Join Date: Jun 2003 Location: Saskatoon, SK TLCA# 8113 Posts: 911	It took these numbers and divided by 2 as there is no intake on the combustion stroke (thanks 83bj60) 600 cfm flow rate is 16990L/min 4L engine at 2500rpms is 10000L per minute/2 is 5000L/min With a .5 drop at 15psi (according to the intercooler specs) It sounds OK to me. I guess the bigger you go the better cooling you could have. You will also suffer from greater turbo lag the bigger you go. Not a concern for me. __________________ Brad T 88 HJ61 "Marmaduke " 12H-T, A440, extreme valve body, PI, cable lockers, PTO winch, SOA, 2" body lift, FF, ARP studs, Longfields, 5.29s, 38x14.5R16 Toyo MTs... 78 BJ 40/42/60

03-12-08, 10:01 PM	#16
JoeCanadian IH8MUD Regular Join Date: Nov 2006 Location: Campbell River BC on Vancouver Island in Canada on Earth Posts: 227	looks highend to me, good job man __________________ BJ60 TURBO 3B ,2 1/4" exaust pipe, Custom rear frame and 33x12.5/r15 Hankook Dynamic MT, bj74 springs frunt and rear, fixed 90% of body rust and painted metallic money green and truckbed liner. her name is "The Screaming Green Submarine"

03-16-08, 11:42 PM	#17
BURGER IH8MUD Junior Join Date: Jun 2005 Posts: 159	So how are things working out on this?? Pics??? Numbers?? __________________ 1986 hj61,h55f,cable lockers,pto,2" lift, 33/10.5r15 at's,safari snorkel,grainger valve,2.5 inch exhaust

03-17-08, 08:32 AM	#18
The Dude IH8MUD Addict Join Date: Jun 2003 Location: Saskatoon, SK TLCA# 8113 Posts: 911	Well, like all projects that initial look simple, when you actually get right down to it and start tightening things back up, I ran into a few problems. The intercooler has to sit about an inch lower then in the previous pictures. That means that I had to cut the lower valance and repaint. I also needed to cut out the back of the grill a lot more then I thought. I also had to repaint my holes that I cut through the body. I am also awaiting two more 45* silicon elbows. My other issues was my tranny cooler. It was to be mounted above the intercooler but didn't fit. I had to search out a much smaller cooler and reinstall. I also ended up installing a PS cooler in front as well for my hydro assist. While I was at it I decided to black out the grill and headlight trim. That meant blasting and painting all the plastic trim. I also went black on the intercooler so that it doesn't stand out. It's coming along. I will get some new pictures up tonight. __________________ Brad T 88 HJ61 "Marmaduke " 12H-T, A440, extreme valve body, PI, cable lockers, PTO winch, SOA, 2" body lift, FF, ARP studs, Longfields, 5.29s, 38x14.5R16 Toyo MTs... 78 BJ 40/42/60

03-17-08, 10:58 AM	#19
The Dude IH8MUD Addict Join Date: Jun 2003 Location: Saskatoon, SK TLCA# 8113 Posts: 911	I hope engine cooling won't be an issue... Not sure what I am going to do about that if it is. The Toyota is going to go body color and I will reinstall the red diesel trim piece. __________________ Brad T 88 HJ61 "Marmaduke " 12H-T, A440, extreme valve body, PI, cable lockers, PTO winch, SOA, 2" body lift, FF, ARP studs, Longfields, 5.29s, 38x14.5R16 Toyo MTs... 78 BJ 40/42/60

03-23-08, 01:18 AM	#21
BURGER IH8MUD Junior Join Date: Jun 2005 Posts: 159	Did the piping you buy from just intercoolers come with the ends beaded or rolled to stop the silicone couplings and elbows from blowing off. Does it need to have these beaded and/or rolled edges Also does anyone know what the hump couplings are for? I found a site that say its to build a high pressure intake? Not sure what that means though. Is it the side from the turbo to the intercooler or is it the side from the intercooler to the intake? Why do no other silicone parts come with the hump. I've said hump way too many times...gotta go now __________________ 1986 hj61,h55f,cable lockers,pto,2" lift, 33/10.5r15 at's,safari snorkel,grainger valve,2.5 inch exhaust Last edited by BURGER; 03-23-08 at 01:31 AM.

03-23-08, 05:01 PM	#22
Cañonero IH8MUD Junior Join Date: Jul 2007 Location: Asturias(Spain)-London(England) Posts: 176	Haven't you considered this option: [IMG] http://img182.imageshack.us/my.php?image=hdj55cv0.jpg [/IMG] [IMG] http://img401.imageshack.us/my.php?image=hdj56aa0.jpg [/IMG] [IMG] http://img257.imageshack.us/my.php?image=hdj57rn8.jpg [/IMG]

03-24-08, 06:25 AM	#24
Cañonero IH8MUD Junior Join Date: Jul 2007 Location: Asturias(Spain)-London(England) Posts: 176	Yes, I've heard about that problems of the top mounted intercooler. The thing is I have the chance of getting the whole top mounted kit, including the bonnet vent, for a very low price, and it would be much costly to get the front mount kit. I have clear that the front mount is a better option, but, what about fitting the top mount one and a big fan under it? Would it work?

04-02-08, 01:22 AM	#26
panoramic IH8MUD Regular Join Date: Jul 2006 Location: Austin,Tx TLCA# 15991 Posts: 228	Any status update? If this works well, I might try to duplicate it on my FJ40/12HT.... __________________ N6LG - Extra Class Amateur Radio Operator 1982 FJ40 (HJ41), 12HT turbo diesel, H55, ARB locker, e-locker, Marks Gears, APRS 1997 LX450, 1HT-FT/H151 diesel conversion in process... 1972 FJ40 Fun Beater Rig, Bone Stock!

04-02-08, 08:13 AM	#27
The Dude IH8MUD Addict Join Date: Jun 2003 Location: Saskatoon, SK TLCA# 8113 Posts: 911	It should be rolling tonight or tomorrow night for sure! __________________ Brad T 88 HJ61 "Marmaduke " 12H-T, A440, extreme valve body, PI, cable lockers, PTO winch, SOA, 2" body lift, FF, ARP studs, Longfields, 5.29s, 38x14.5R16 Toyo MTs... 78 BJ 40/42/60

04-02-08, 03:57 PM	#28
The Dude IH8MUD Addict Join Date: Jun 2003 Location: Saskatoon, SK TLCA# 8113 Posts: 911	WOOHOO I could only do a short run as I ran into some coolant leaks. The truck was up to normal operating temps and I had two WOT runs hitting 1200* max on the EGT. I can't say if the EGTs are down yet as I didn't have it out long enough. I did noticed increased turbo lag of a second or two. No lost boost that I can tell. On the hot side, I was getting readings of 90-100F right at the turbo and 86-88F on the hot side of the intercooler On the cold side I was 64-66F at the intercooler and 58-60F right at the intake. __________________ Brad T 88 HJ61 "Marmaduke " 12H-T, A440, extreme valve body, PI, cable lockers, PTO winch, SOA, 2" body lift, FF, ARP studs, Longfields, 5.29s, 38x14.5R16 Toyo MTs... 78 BJ 40/42/60