12HT Top Mount Intercooler install and assistance

[Spudman]

Spuds, two thoughts.
Silicone Tubing for boosted vehicles. I don't know what the diameter is but if you measure and cut the original piping, you could make a nice flange. Secong thought, what does that 3bolt flange connect to and is it possible to delete it? Then you could run piping straight in.
Looking at the pics above I think he, cut and welded aluminum pipe.
Do you have access to an Aluminum welder?
If you know someone or could hire someone its a pretty simple job!

That being said, you should check out a Subaru wrx intercooler, it'll give you more flow and the I/C dumps downwards so you you sit it over the intake as opposed to the valve cover.
Spuds what are you going to do for heat shielding and mounting?
Any idea what pressure that blow off valve/ recirculation valve engages?
I have a good amount of experience with boosted vehicles.
What kind of power are you trying to run? The intercooler will reduce intake charge temps, but are you going to increase boost and fuel as well? I love diesel motors. They're full throttle all the time and you vary RPM by changing the fuel content in the engine. Brilliant!

I think you're on the right path though!

Hey mate

Thanks for the comments, hopefully I will be able to pull that flange off next weekend and have a really good look, I can't weld aluminium and being a super small town I don't know anyone that does.

As for what am I trying to achieve, well this is my first turbo diesel and I would like to intercool it. Haven't looked at boost etc. yet.

Spudman

 

[ozwallaby]

Another thought, Australia, Canada and New Zealand need to come back to Imperial measurements. Us and England are all lonely! I mean we all speak the sane language, like the same stuff, and drink the same beer.

You can't even get a gallon right...

Without looking on the net.... what's a rood.....

Go metric....

 

[Spudman]

Hey Callahan

Maybe it's because we are moving forward, I'm sorry to say but as much as everyone thinks,we don't always follow America

 

[ozwallaby]

@ Ali v..... hook up your I/C thermo so it sees boost, so as soon as you are boosting it comes on.... there is no real loss with a system that does this.... boost will make the inlet temp rise, so it stands to reason that is a good signal for the I/C thermo.... if you have a 60/12ht use the green light on the dash as a signal to a relay to switch the thermo on... done...

 

[ozwallaby]

Hey Oz

Not trying to sound like a noob, but unfortunately I am one when it comes boost, intercooler a and turbos this being my first. I have no idea how to do any of the things you have asked

Can you please write up in this thread, as it will hopefully assist others a how to on those things you mentioned.

Thanks

Spudman

The idea behind what I've said is to actually measure air temp (before the turbo and after the I/C and ideally boost and exhaust) ALL at the same time.... it will be good for comparison purposes if these measurements can be taken before the I/C is installed so you will then have some sort of comparison between intercooled and not... ie did you get any actual measurable benefit or did you spend your money and just get more pipes under the bonnet....

You would need more temp sensors..... digital because they are recordable to computer and can be viewed on screen at the same time.... I think it was Matt McGinness (sp) who had a great set of numbers when he was doing the laminova intercoolers... this is all in an ideal world of course....

 

[Spudman]

The idea behind what I've said is to actually measure air temp (before the turbo and after the I/C and ideally boost and exhaust) ALL at the same time.... it will be good for comparison purposes if these measurements can be taken before the I/C is installed so you will then have some sort of comparison between intercooled and not... ie did you get any actual measurable benefit or did you spend your money and just get more pipes under the bonnet....

You would need more temp sensors..... digital because they are recordable to computer and can be viewed on screen at the same time.... I think it was Matt McGinness (sp) who had a great set of numbers when he was doing the laminova intercoolers... this is all in an ideal world of course....

Oz

I understand that an intercooler is to provide cold/cool air which in effect increases the power of the vehicle, so obviously the temperatures that are going to obtained after the intercooler has been installed, are going to be cooler. Is that not the theory.

So I don't think we spend more money to get more pipes under the bonnet, all newer vehicles that have a turbo diesel are now fitted with an intercooler so someone realised there's more benefit than more pipes under the bonnet.

With gauges, I'm actually looking at round ones and analog to keep the dash looking the same, I've looked at the digital gauges and unless they're right on top of you, you can't adjust them anyway.

If I'm wrong in my theory I would gladly like to be corrected.

 

[ozwallaby]

The idea behind what I've said is to actually measure air temp (before the turbo and after the I/C and ideally boost and exhaust) ALL at the same time.... it will be good for comparison purposes if these measurements can be taken before the I/C is installed so you will then have some sort of comparison between intercooled and not... ie did you get any actual measurable benefit or did you spend your money and just get more pipes under the bonnet....

You would need more temp sensors..... digital because they are recordable to computer and can be viewed on screen at the same time.... I think it was Matt McGinness (sp) who had a great set of numbers when he was doing the laminova intercoolers... this is all in an ideal world of course....

Oz

I understand that an intercooler is to provide cold/cool air which in effect increases the power of the vehicle, so obviously the temperatures that are going to obtained after the intercooler has been installed, are going to be cooler. Is that not the theory.

So I don't think we spend more money to get more pipes under the bonnet, all newer vehicles that have a turbo diesel are now fitted with an intercooler so someone realised there's more benefit than more pipes under the bonnet.

With gauges, I'm actually looking at round ones and analog to keep the dash looking the same, I've looked at the digital gauges and unless they're right on top of you, you can't adjust them anyway.

If I'm wrong in my theory I would gladly like to be corrected.

What you're saying is correct to some degree..... but just because you have an intercooler doesn't mean there is a benefit...... IF someone had a completely mismatched setup (ie intercooler too small or restrictive or absorbing more heat that it dissipates because of bad positioning and numerous other scenarios) they could have an intercooler and actually be going slower or developing less power...... what I'm saying is unless you actually have some numbers/data of some sort, how do you know you haven't spent your money and had very little or no gains... and in fact you may be worse off.....

 

[Spudman]

What you're saying is correct to some degree..... but just because you have an intercooler doesn't mean there is a benefit...... IF someone had a completely mismatched setup (ie intercooler too small or restrictive or absorbing more heat that it dissipates because of bad positioning and numerous other scenarios) they could have an intercooler and actually be going slower or developing less power...... what I'm saying is unless you actually have some numbers/data of some sort, how do you know you haven't spent your money and had very little or no gains... and in fact you may be worse off.....

Ah Ha! Now I understand what your saying, thanks for the clarification Oz.

My intercooler is off a 4.2 turbo diesel Patrol, so I assuming/hoping it is big enough and I understand that also to obtain the maximum benefit the intercooler needs to be sealed when the bonnet closes.

Thanks mate

 

[Spudman]

Oh yeah, I forgot to mention, what I'll do is order the pyro and boost gauges now and I'll fit them before I fit the intercooler and then when I get the readings I'll be able to tell if it's all worth it or not

 

[Spudman]

Today I ordered these gauges, one pyro and one boost

When they hit a pre determined temperature or maximum boost it sets off an alarm and the gauges go red

With the 61 series they have a perfect space for gauges next to the heater controls

Spudman

 

[Callahan Offroad]

Great looking gauges!

 

[Spudman]

Thanks mate

 

[Spudman]

So wanting to get moving on and fit this intercooler, I decided today to make my own intake manifold bracket

And then I'm going to weld some 2 inch steel in the hole

And then I'll be able to fit a 90 degree rubber hose which will fit onto the intercooler.

Spudman

 

[Spudman]

I've welded up the bracket and also put in the little boost pipe, I found a little piece of tubing with 2 ends coming out so that I can plug my boost gauge directly onto this, which I hope will give a more accurate reading

Spudman

 

[maat]

looking good mate! keep the pics coming

 

[Spudman]

Thanks mate

Hoping to do a bit of a mock setup tomorrow, see if I can get everything in place and then workout how I will secure the intercooler to the engine

Hopefully shouldn't be too far away

Spudman

 

[Callahan Offroad]

Hey! Now we're talking!

 

[ali v]

Ali your a breath of fresh air and your local too

I haven't actually fitted mine up yet, cause I'm still searching for one of those mounting brackets in your last picture.

Did you make it up yourself or purchase it.

If you're making them I'd be very interested in one

Your setup looks good mate

Spudman

Sorry Spudman, looks like I'm a bit late to answer your questions... Sounds like you're all sorted tho - looking good.
Just fyi tho I got a flange laser cut from aluminium. I used a gasket that I had lying around as a template.
The pipe I used is 63.5mm od x 6.3mm wall. A bit thick I know but I wanted the ID of the pipe to roughly match the bore in the intake so I didn't have a big step there.

btw I wish I was a bit more local to your home town - been up that way a couple times before and it's a beautiful place.

 

[ali v]

@ Ali v..... hook up your I/C thermo so it sees boost, so as soon as you are boosting it comes on.... there is no real loss with a system that does this.... boost will make the inlet temp rise, so it stands to reason that is a good signal for the I/C thermo.... if you have a 60/12ht use the green light on the dash as a signal to a relay to switch the thermo on... done...

Thanks Ozwallaby,
It definitely sounds like the simplest way. My reasoning for going with a temperature switch was that with the boost switch, as soon as you go off boost the fan will switch off even if the intercooler itself is still very hot (after all its a big heat sink). Temperature seems a bit more relevant to me... But if I can't get the right temperature switch then I'll probably consider doing what you're suggesting. Another problem with a temperature switch is it means I've gotto plumb it into the intake flange or the intercooler end tank.

 

[Spudman]

Thanks Ali

Thought we'd lost you mate.

Yeah I think I've got it sorted, hopefully tomorrow will tell.

Yes the Kimberley is an awesome place, we're just towards the end of our wet season, still bloody hot. Certainly looking forward to dry, our so called winter.

If you're up this way give me a shout and I'll show you around

Spudman