HJ-61 intercooling thread. (1 Viewer)

[Talos]

howdy.

well, I bought me a intercooler today, went the front mounted air to air route.

and here it is :

and a few pics of my mounting exercises

got the front stripped.

a bit on the larger side.

I´ll be cutting the oval holes on either side of the intercooler to fit the pipes.

made a bracket from a 50x50mm L iron.

need just 1 inch to make the grille snap into place.

was thinking about bending the wall in so I can mount it a bit near the radiator, that or cut 1 inch from the grille...

well that´s it for now, anything I should do diffrent?

 

[roscoFJ73]

Nice work. Will your radiator stay cool enough? I guess Iceland is different , I wouldn't be able to do that here in summer.

How much more power do you expect?

 

[Talos]

well I am a bit concerned about blocking the radiator like that but I´ll just have to cross that bridge when I come to it

would probably fill the fan clutch with sikaflex so it´ll pull in more air, did that on my 3L hilux that had heating problems.

don´t know about power increases but I´m hoping to get maybe 10-20% more HP and torque.

 

[Tapage]

nice .. !

thought you are not planning run the factory grill and what do you think for pipes route .?

 

[Talos]

well If I can´t get the stock grille to work I might look into using aluminium mesh grille, but belive I can shim the stock one to fit, I´ll jsut have to work up the courage to go at it with a sander

the pipes won´t be much of a problem I think, I´ll just have to relocate the black canister on the driver´s side (vacum resevoir?) a little and make an elbow for the intake.

the pipes will come into the engine room under the batteries and up to the motor on each side.

I´ll post pics as I go along.

 

[Tapage]

Here coul be a problem to me front intercooler ( due to our hot weather)

 

[Dougal]

Here coul be a problem to me front intercooler ( due to our hot weather)

Do you have any overheating problems at the moment?

 

[troopie]

Looks good.

I just finished an intercooler build on my 12ht powered Troopie and it really works. I guess that the horse power improved with 10 to 15% and torque with 15 to 20%.
I did a test run last sunday. 15 minutes at 100MPH (which is downright scary btw). It raised the engine temp just a little but the biggest surprise was that the cool side of the intercooler was actually cold, not even close to warm. Not bad for a $75 ebay intercooler. When money permits i'll have it dyno'd and get you the results.

I'm off to Germany this weekend to do some low flying on the Autobahn and offroading.

 

[goldchaser]

i bet you left finger impressions in the steering wheel after driving a troopy at 100mph for 15 mins,thats gotta be some kind of world record.
cheers goldchaser

 

[troopie]

i bet you left finger impressions in the steering wheel after driving a troopy at 100mph for 15 mins,thats gotta be some kind of world record.
cheers goldchaser

Actually, i was afraid because eventhough i got 4 wheel diskbrakes, i know the brakes are not up to the task to slow the Cruiser down fast enough in an emergancy. The speed itself was doable, no shakes at all and i was still steering one handed. But the noise....

None the less. Nothing any one should do on a daily basis. It was just a test withresults.

Cheers,
Mark

 

[Tapage]

Do you have any overheating problems at the moment?

No and yes ..

No coz usually off road or city driving means no problems at all with no more ( never even with AC on ) than 1/4 temp gauge .

Yes, when I'm pushing it hard ( means 14 PSI ) in the HW for more than 20 - 30 min it raise in the gauge up to middle .. that not really meand " overheating " as is .. more it's not usual.

I have top mounted intercooler and huge hood scoop but I was reading about the hood scoop efect in the air circulation throught the rad .. but right now I'm not sure If I have a real problem.

 

[Talos]

took a big part of today to finish the "intercooling"

first I had to make an 180 degree bend to the intake, used 2 1/2" stainless steel pipes, Tig welded 2 elbows together, I´ll let the pics do the rest of the talking

that one was actually not that hard to make, had a bending machine to aid me so it was quick work, the stainless steel pipe didn´t bend all that well, but hey it looks ok.

the monster in front.

passenger side.

it actually looks good without the grille



performance vise it goes like crap now wen I floor it I hear the turbo spool up but it´s followed by a hissing sound so it´s blowing out air somewhere on the way.

the thing is, the boost gauge shows boost, 10 psi, but it´s connected to the wastegate line, will it show boost if it´s blowing out?

anyways, hope to find the leak tomorrow.

another thing, there was a small hose connected to the aluminium piece from turbo to engine, isn´t that just for the factory turbo light? I just blocked it.

 

[Tapage]

another thing, there was a small hose connected to the aluminium piece from turbo to engine, isn´t that just for the factory turbo light? I just blocked it.

I thought yes ..

Your setup looks incredible clean .. congrats.

 

[Talos]

Your setup looks incredible clean .. congrats.

thank you very much

I went through all the hose clamps and stuff and didn´t find any leaks, (sounds like it´s comming from the turbo it self, at least on that side of the engine bay)

Can the hose that connected to the intake limit the boost somehow?

I can feel a little power surge when it´s building up boost to about 3 psi then the hissing sound begins and it´s just blowing air into, well, the air

well anywho I´ll weld something to the intake bend to connect it again on tuesday, just wanted to know beforehand if this indeed could be the problem.

 

[Dougal]

thank you very much

I went through all the hose clamps and stuff and didn´t find any leaks, (sounds like it´s comming from the turbo it self, at least on that side of the engine bay)

Can the hose that connected to the intake limit the boost somehow?

I can feel a little power surge when it´s building up boost to about 3 psi then the hissing sound begins and it´s just blowing air into, well, the air

Some intercooler systems just sound like they've got a boost leak, even when they haven't. The 100series 1HD-FTE sure does.

 

[Talos]

Some intercooler systems just sound like they've got a boost leak, even when they haven't. The 100series 1HD-FTE sure does.

ok, so it might just be I need more boost/fuel.

 

[troopie]

another thing, there was a small hose connected to the aluminium piece from turbo to engine, isn´t that just for the factory turbo light? I just blocked it.

This is actually an important hose. It feeds pressure to the injection pump so it will increase fuel delivery on boost. Without it you´ll end up with a direct injected 2H with a useless turbo and intercooler. Connect that hose and you´ll see a big improvement in power.

HTH,

Mark

 

[Talos]

help?

This is actually an important hose. It feeds pressure to the injection pump so it will increase fuel delivery on boost. Without it you´ll end up with a direct injected 2H with a useless turbo and intercooler. Connect that hose and you´ll see a big improvement in power.

had to be

well I connected the hose, some power increase and the hissing sound stopped

anywho, seeing as I had a working engine I couldn´t let it be, turned up the fuel 2 circles CCW (EGT didn´t go up so I´m wondering if this is the right turning direction?) pumped the boost to 10 psi, no problem, then I turned the boost up some more and when it hit 14 psi I heard a bang from the engine, like a hose blowing, and lost power, so after soiling my self I checked the engine bay and couldn´t find anything wrong, so off I went with a little less boost and bang it happened again.

Now the boost gauge won´t show anything over 4 psi (lots of power though).... anybody have any idea what went wrong? does the wastegate have some overboost feature?

 

[Tapage]

Where do you have the hose from the valvle cover . ? to the air filter box . ?

First thing that I blow .. my boost gauge hose ..
Second thing that blow the silicone elbow at the throtle body ..

 

[Talos]

yea it´s probably the gauge that´s gone, since all the power is still there but the damn thing only shows 4 psi.

where do you guys put your boost gauges? I have mine connected to the hose that goes to the wastegate, thinking about putting it in at the intake, after the intercooler.