just a question, why are you locating it behind the engine and infront of the firewall? Seems like there should be plenty of room elswhere in the engine compartment? otherwise I enjoy your stick to it ness on this project and creative talent
Build Another Prado in Montana
- Thread starter AirheadNut
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- Thread starter
- #822
Good question, and probably one I should reconsider. One of my main goals with this swap is to declutter and simplify the engine bay as much as possible, while prioritizing serviceability of any normal wear components or routine maintenance items. The intercooler isn't something that should have to be serviced often, if at all, so I figured I could take advantage of the extra space behind the engine by putting it there. However, the more I look at it I realize that it may be more work for a less than optimal intercooler than it is worth. I need to repopulate the engine bay with some of the other engine related components and see what kind of space I have left, and if it makes sense to find an off the shelf intercooler that will mount somewhere else in the engine bay.just a question, why are you locating it behind the engine and infront of the firewall? Seems like there should be plenty of room elswhere in the engine compartment? otherwise I enjoy your stick to it ness on this project and creative talent
- Thread starter
- #823
I pulled the air filter housing out of my Jetta to see how that would fit in the Prado. It does fit, just, but the inlet and outlet are in totally the wrong places. Upon further measurement I realized that none of the Donaldson filters I was considering will fit either, so I'm thinking the best option will be to design a filter housing around the stock Passat filter. That will allow me to put the inlet and outlet right where I need them, and the filter size is just right for the space I have.
I also started un-modifying my radiator. Since the front mount intercooler no longer fits, the radiator can move back to its original location so I needed to revert the RH side mount bracket to stock. With only about 4 hours of TIG practice on aluminum it isn't going to win any prizes, but I think it will hold up just fine. I'll go back over it to fill the keyholes and weld the entire seam before reinstallation.
I also started un-modifying my radiator. Since the front mount intercooler no longer fits, the radiator can move back to its original location so I needed to revert the RH side mount bracket to stock. With only about 4 hours of TIG practice on aluminum it isn't going to win any prizes, but I think it will hold up just fine. I'll go back over it to fill the keyholes and weld the entire seam before reinstallation.
- Thread starter
- #824
The postman delivered the alternate accessory bracket and related parts, so I bolted them on.
Unfortunately when I went to install the AC compressor I discovered that it interfered with my new motor mount bracket by about 3/4". I think there is just enough room to move the mount back by that amount, but it will be tight. I could also get an AC delete pulley, but I'd really like to retain the possibility of getting the AC system working again.
This discovery took the wind out of my sails this afternoon, so I finished welding up the radiator mount instead. Full weld on both sides of the seam.
Unfortunately when I went to install the AC compressor I discovered that it interfered with my new motor mount bracket by about 3/4". I think there is just enough room to move the mount back by that amount, but it will be tight. I could also get an AC delete pulley, but I'd really like to retain the possibility of getting the AC system working again.
This discovery took the wind out of my sails this afternoon, so I finished welding up the radiator mount instead. Full weld on both sides of the seam.
- Thread starter
- #825
A friend dropped off a couple of old Volvo air filter housings, one from a 240 and one from a turbo 760. Unfortunately they were both too deep to fit so I started drawing up a custom air filter housing that takes a stock Passat air filter.
I had some leftover 0.080" thick aluminum sheet from work, so I started fabbing up the parts. The old Di-Acro brake is working pretty well after a quick tune up.
The Fireball Tool fixture plates and fixturing tools are really handy.
I had some leftover 0.080" thick aluminum sheet from work, so I started fabbing up the parts. The old Di-Acro brake is working pretty well after a quick tune up.
The Fireball Tool fixture plates and fixturing tools are really handy.
- Thread starter
- #826
My TIG welding has improved some but still needs plenty of work, don't look too close at the welds! I got the bottom half of the filter housing welded up, then put a piece of 1/4" plate across the opening and welded it on.
I cut a hole in the 1/4" plate for the filter element to fit in.
I cut a hole in the 1/4" plate for the filter element to fit in.
JDM Journeys
Moderator
It looks good from far! And I'll bet it ain't far from good either...
Nice work!
Nice work!
- Thread starter
- #828
This afternoon I got the top half of the air filter housing put together. I think it turned out ok but I'll know for sure when I get some latches on it and can test it for leaks around the filter. It fits pretty much exactly as I intended it to. The lid will clamp on with some adjustable over-center draw latches.
I'll plumb the inlet to the factory location in the fender, considering a snorkel to help reduce dust ingress since I no longer have the benefit of a cyclonic type filter.
I'll plumb the inlet to the factory location in the fender, considering a snorkel to help reduce dust ingress since I no longer have the benefit of a cyclonic type filter.
- Thread starter
- #830
Yesterday evening @2gbFlashDrive came over and helped me pull the Prado into the shop and remove the engine. I cut the LH motor mount bracket off the frame and moved it back about 7/8", then cut apart the engine side bracket so I could modify it to fit. There is just barely enough clearance between the motor mount and oil cooler, but now the AC compressor fits and has enough space to bolt manifolds on.
