12HT intercooler adaptor at intake? Anyone have photos of one?

[helocat]

12HT intercooler adaptor at the intake. Can't seem to find a photo of one online. Does anyone have photos of one?



Am I on the right track here, just fabricate a flange that mimics the stock turbo intake pipe? So this area, then fabricate the intake off this three bolt pattern?





I don't have the luxury of ordering up a gasket I can pull the dimensions from to fabricate the mount. I will have to pull the intake crossover pipe to get the data. Any chance this info is online? If not I will put it online once I am done.

(Side question, is that butterfly valve below the intake the valve chokes off the air and shuts off the engine?)

 

[Tapage]

IIRC there is no butterfly valve in the 12H-T .. 2H ( NA brother ( does have butterfly )

 

[Christian]

Tapage: there is a valve, just like Helocat says it shuts the engine down, not like the pump regulating one on the 2H. I have never seen that way of shutting down a diesel on any other, but it makes a runaway impossible.

Off with the intake pipe and make a template...

 

[blis]

Tapage: there is a valve, just like Helocat says it shuts the engine down, not like the pump regulating one on the 2H. I have never seen that way of shutting down a diesel on any other, but it makes a runaway impossible.

Off with the intake pipe and make a template...

That's correct, 12ht uses butterfly valve for shutting down the engine...

And yes, you are correct on your thoughts. Just remove the crossover pipe and get measurements for a flange... When you remove the crossover pipe the butterfly valve is clearly visible...

 

[helocat]

Tapage: there is a valve, just like Helocat says it shuts the engine down, not like the pump regulating one on the 2H. I have never seen that way of shutting down a diesel on any other, but it makes a runaway impossible.

Off with the intake pipe and make a template...

That's correct, 12ht uses butterfly valve for shutting down the engine...

And yes, you are correct on your thoughts. Just remove the crossover pipe and get measurements for a flange... When you remove the crossover pipe the butterfly valve is clearly visible...

Thanks guys. I am doing a custom built intercooler right now so in a few weeks I will pull the intake and draw up the flange adaptor. Once I draw it up I will share the CAD file for it online for others.

Mark

 

[Tim-HJ61]

We just took the gasket to a laser cutting shop and they copied it. They had a minimum price of about $60, and for that we got three IIRC in 10mm stainless.

The funny thing was that one of the holes in the gasket had torn, so there was a gap on the outer side of the hole, and that's how our flanges came back.
we said copy, that's what they did!

Something heavier than 10mm would be better to try to limit the distortion from the welding, or alternatively file or machine the face flat again.

Tim

 

[helocat]

We just took the gasket to a laser cutting shop and they copied it. They had a minimum price of about $60, and for that we got three IIRC in 10mm stainless.

The funny thing was that one of the holes in the gasket had torn, so there was a gap on the outer side of the hole, and that's how our flanges came back.
we said copy, that's what they did!

Something heavier than 10mm would be better to try to limit the distortion from the welding, or alternatively file or machine the face flat again.

Tim

Hmm I was thinking doing it in aluminum but stainless would be more consistent with the rest of the IC. I can cut the flange out of some 1/2" (12mm) 304 Stainless bar stock on my mill. If I machine it I can then cut all the surfaces down .050" so its dead on flat. Of course it will be .490 thick but welding .065" stainless tube to it for the intake will not get hot enough to warp a plate that thick.

I probably should just machine the exhaust flange from the same materiel.

Mark

 

[Christian]

I would like one cut on a lathe with a reducer from the 2.5" intercooler hose down to the actual intake Ø. The flange and reducer could be one piece, with the flanges outer sides cut to fit afterwards. But I don't have the tools for it...

 

[helocat]

I would like one cut on a lathe with a reducer from the 2.5" intercooler hose down to the actual intake Ø. The flange and reducer could be one piece, with the flanges outer sides cut to fit afterwards. But I don't have the tools for it...

The intake is smaller than the 2.5" tubes most use? So you are looking for better flow into the intake, vrs the flow being disrupted by the surface of the intake lip.

Hmm, will have to get my intake off to look at it. I don't have the lathe, but I do have a CNC mill and full surfacing software. I could 3D cut the ID to flow the air directly into the shape of the intake. This would put the flange and the reducer into one part. I would go back to aluminum if I was do that, material cost and machine time needed being the #1 reason. (Talking a 2" thick block, big $$ in 304SS) Will have to look at it and see if I have the time available to machine that. (my business kinds of gets priority over my personal projects, these days)

Mark

 

[Christian]

The intake is smaller than the 2.5" tubes most use? So you are looking for better flow into the intake, vrs the flow being disrupted by the surface of the intake lip.

Hmm, will have to get my intake off to look at it. I don't have the lathe, but I do have a CNC mill and full surfacing software. I could 3D cut the ID to flow the air directly into the shape of the intake. This would put the flange and the reducer into one part. I would go back to aluminum if I was do that, material cost and machine time needed being the #1 reason. (Talking a 2" thick block, big $$ in 304SS) Will have to look at it and see if I have the time available to machine that. (my business kinds of gets priority over my personal projects, these days)

Mark

Hi Mark

That sounds like something that would sell quite easily, if the price was reasonable of course!
I'd go with alu, cheaper, faster to cut, gentler on the tooling and matches the original material.
A hop-up option could be to replace the original butterfly housing with a bigger one maybe using an universal throttle body from Ebay or alike, matched to the toaster flange on one side and with 2.5" silicone hose coupler on the other?

 

[BaileyG]

Thanks guys. I am doing a custom built intercooler right now so in a few weeks I will pull the intake and draw up the flange adaptor. Once I draw it up I will share the CAD file for it online for others.

Mark

Hey Mate

Did you happen to draw up a CAD file for the flange? How did it go in the end?

Trying to get a flange made up to use a 12ht crossover on a 2h throttle body. The idea is to weld a short length of pipe to the flange the use silicone joiners.

Bailey

 

[relaxedcruiser]

Just to add some pics - that's what I did some months ago: Made a 10mm aluminium plate with the right size hole in it and welded two cast flanges to it.