1hdt laminova intercooler

[sandcruiser]

interested to see how this turns out
I don't understand why you didn't go transverse to the motor (90 degrees from what you did)
but your solution seems to be working so far.... so let's see how it goes

 

[ledgend80]

ok well i have finally come up with how i will finally mount the cooler to the manifold. i had to flip the cooler 180 degrees front to back. so that the cooler can be mounted more to the passanger side of the car to allow me access to the injector lines. (thanks z()ltan for the heads up. as you can see from the pics i have had to rasie up the top plate to allow air to get into the cooler from the turbo. there will also be a funnel fitted here as well. will just have to get a little pipe bender to bend the dipstick tube. and re do the accelarator (may do like z()ltan has done) also have another idea.

will try and get the ally bent up this week so i can see how it will all look.
if anyone can see any other problems i may have let me know

 

[ledgend80]

ok well got the rest of the ally bent up today for the cooler and is starting to take shape. and the sheetmetal guy did a good job bending it up. espically the bit below the cooler to fill in the manifold.
cooler welded to manifold

cooler welded to manifold

top plate so air from turbo can access the cooler

side view of top plate

lower manifold infill piece

plenum in postion

plenum in postion

the plenum still needs to be modified i still need to take bout 10mm out of the hight and will need to take some off where the plenum touches the cooler so the plenum doesn't cover the rocker cover.

 

[matt.mcinnes]

Very nice indeed.



You do realise once you make this one, they will all want one

 

[sandcruiser]

looks like very nice fabrication

seem as if air will mostly flow over the first air/water tube, but not so much across the last one.

 

[Tapage]

seem as if air will mostly flow over the first air/water tube, but not so much across the last one.

the complete heat exchanger will be full of compressed air .. ( compressed hot air ) not a big deal ..

 

[ledgend80]

hey sandcruiser the air should flow evenly across them all. air from the turbo comes into the plenum and then above all the cores which will make an even bigger plenum. the slots in the tubes are going from top left to bottom right straight into the manifold. if the slots in the tubes were going from topright to bottom left then i would agree with what you are saying. but saying that with the pressure from the turbo it will fill the cooer up anyway and the air will flow anyway. just with the way i have the slots in the tubes running from top left to bottom right seems as it is the best option that i could come up with.

 

[ledgend80]

Very nice indeed.



You do realise once you make this one, they will all want one

so then you will be busy making them for the 1hdts then.

 

[matt.mcinnes]

so then you will be busy making them for the 1hdts then.

I can alter the end plates to simplify fabrication for you

 

[ledgend80]

what would you change on the end plates

 

[sandcruiser]

very cool

 

[matt.mcinnes]

what would you change on the end plates

Just make them so you don't need to fold the top edge over at the ends.

 

[awill4x4]

Looking at how you have notched out the inlet manifold, I think the better version would have been similar to the latest Nissan TD42 one Matt
and I built into the manifold.
Yes it's a bit higher but it doesn't overhang the manifold nearly as much with good air flow into the manifold particularly at the rear.
Regards Andrew.

 

[ledgend80]

the biggest problem the whole time has been bonnet clearance and if i was to go with the nissan style i wouldn't be able to shut the bonnet at all. i would of liked to of been able to centre the cooler on the manifold but then you have issues with getting to the injector lines.

also with the 1hdt the accelerator linkage bolts to the back of the manifold under where the cooler sits. if that wasnt there then i could of notched the back of the manifold out tobetter air flow.

the joys of modifying something that wasn't meant to be there and making it look like it was meant to be there.

 

[ledgend80]

ok just thought i would put a bit of a pic up of the air flow through the cooler for those trying to work it out.

 

[ledgend80]

ok time for a little update. finally deciced on end design and got the boily to do some welding. just need to get the plenum welded and then i can pressure test it.

was suggested that i put some extra support under the bootom of the cooler where the extra overhang is. spoke to the boily at work and he said it should be alright with out it because the end plates are welded into the intake manifold and act as support. so what is everyones opinon supports or no supports.

 

[lshobie]

I am definitely interested in this setup. Looks great.

 

[ledgend80]

ok so the cooler is fully welded and now just needs to be pressure tested

bit of an internal view

showing the core going into the cooler

close up of the core

end caps with fittings

the back 2 fittings will have to be turned up away from the manifold as the hoses will hit the manifold

upper filler point

changed the r/h water inlet to what you see because i couldnt get the grill to go back on

had to move the right hand fan down to be level withthe left hand one so when i run the hoses i can fit the grill

 

[Tapage]

dude .. I wish I had your welding skills .. !

 

[ledgend80]

dude .. I wish I had your welding skills .. !

yeah i wish i could weld like that to. credit has to go to the boilermaker at work.