Build Dirty Koala Build - Cummins Common Rail + NV4500 + HF2AV Swap

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IMO air to water is the best solution for a turbo diesel in rig like this, especially if you plan for any low speed wheeling or rock crawling. You just don't get the airflow with air or air in those situations. Air to water while more complicated in general are far easier to install as there are many more mounting options and locations to choose from.
 
bigfj62 said:
IS there a photo of your intercooler placement in your build thread. Manual trans route will free up some space by getting rid of the trans cooler. I am not a fan of the placement either. Aren't most domestic diesel trucks coming off the factory lines running their coolers in a similar location. It is not optimal to say the least but I think if you build some armor around it in some way I don't think it would be a huge issue. Is there any room for a top engine mount hood scoop cooler? Just throwing an idea out there.
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Best I can do. These were on my phone.
ImageUploadedByIH8MUD Forum1424283361.078253.webp
ImageUploadedByIH8MUD Forum1424283378.395596.webp
 
Dubbinchris said:
IMO air to water is the best solution for a turbo diesel in rig like this, especially if you plan for any low speed wheeling or rock crawling. You just don't get the airflow with air or air in those situations. Air to water while more complicated in general are far easier to install as there are many more mounting options and locations to choose from.
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EGTs are so low that an intercooler isn't even needed for slow low range wheeling.
 
Dirty Koala said:
That intercooler is tucked up nice and high, do you have the specs on it?
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It's a Mishimoto. I think I posted specs in my build thread. I'm using the phone app at the moment so I'm somewhat handcuffed. Add get them later today when I get home.
 
Depends on how big the hole is, but it is essentially a boost leak. The turbo spins faster to make the same boost up until it can't make the target boost pressure and then you have a turbo overspeed and you are down on power. Not the end of the world, most likely won't leave you stranded but could kill a turbo if ran like that for a long time.

GLTHFJ60 said:
The fact that the intercooler goes below the tops frame rails is awful in my opinion. The stock 80 series PS "cooler" lines exist in that area and it's a common mod to move them up higher to be away from rocks. Why put an intercooler in that spot? Even if it doesn't go below the frame rails, existing at the level of the bottom of the frame rail is way too low.

What happens if you put a hole in your intercooler on the road from a piece of debris, or from a rock on the trail? Even a piece of gravel kicked up by a truck?

I understand that there are space concerns in the 80 with a 6 cylinder diesel (there are in a 60 as well), but if that's the only spot for an intercooler then I'd be tempted to not run one at all.
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scottryana said:
Depends on how big the hole is, but it is essentially a boost leak. The turbo spins faster to make the same boost up until it can't make the target boost pressure and then you have a turbo overspeed and you are down on power. Not the end of the world, most likely won't leave you stranded but could kill a turbo if ran like that for a long time.
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Overspeeding the turbo can be an instantaneous and catastrophic event. If you are boosting when the rupture happens, it can easily blow the matrix oil seals in the turbo right then and there. Not only do you have a turbo that's consuming a bunch of oil now, but it's possible to cause a runaway condition if the compressor matrix oil seal goes and feeds the intake. There have been a few instances of people on 4BTSwaps using the wrong type of boost elbows and this exact thing happened after a rupture.

Typically a "boost leak", as in a clamp that's not tight enough or a burr on a connection preventing a proper seal, causes the symptoms you describe. If you have a hole in the intercooler or boost tube, depending on the size of said hole, then no appreciable boost will ever be made.

Despite the argument as to how big of a problem it would be for the intercooler to be ruptured, I'd recommend taking steps to eliminate that as a possibility whatsoever, which is centered around finding a better place to mount the intercooler.
 
I would agree, and why I have been against kits like CX racing that puts the intercooler in the exact same spot. I think youre painting the most catastrophic event while I was replying to the question of what happens when you get a pin hole from road debris.
 
I think a .25" thick skid plate under the frame rails would protect the intercooler from rocks, but my question would be whether a skid plate would allow enough airflow for the intercooler to do its job.
 
Dirty Koala said:
I think a .25" thick skid plate under the frame rails would protect the intercooler from rocks, but my question would be whether a skid plate would allow enough airflow for the intercooler to do its job.
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Absolutely not, but in that position, the intercooler is blocked by the bumper anyway, so what is there to lose?
 
Wheelingnoob said:
Any update on the nv4500 to t case adapter yet? Looking forward to see that.
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No update on the adapter yet, I expect it will take a few weeks to get fabricated. My son was born on Sunday, so haven't had much time the past couple of days to spend on the conversion. I will give Dustin a call tomorrow to see how it's progressing.

I have however decided to farm out the cummins rebuild to a professional diesel shop well known in the competiton diesel community...Mumau Diesel in PA. I plan to get the motor out to them sometime in the next two weeks for the special treatment.

Additionaly I was on the fence regarding piston coating, but have determined that the thermal barrier will help keep heat in the combustion chamber, prevent heat soak, run more efficiently and extend life. My goal for this motor is longevity, reliability with a splash of power and torque. As a result I am going to have the pistons sent to Swain Tech Coatings in NY to coat the domes with their Gold Coat Product.
 
JohnVee said:
Congrats on the baby.


...via IH8MUD app
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Crusha said:
Man, he really did not want to enter this world, wasn't the due date the seventh?
Congrats!
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Thanks John and Greg. Yeah he was defintely stubborn. He was due 2/5/15...17 days later we had to pull him out..for the 1st hour he was mad as a cut snake! Being almost 9 lbs and sunny side up...he wasn't going anywhere by himself.
 
OGBeno said:
Congrats Morgan!! Great news sir. New engine and new baby.

:)
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Thanks Onur, new baby, new motor...and sometime soon a new ride for the misses. That little 3 series isn't going to cut it with a baby and 3 dogs. She likes the LX470 and Land Cruiser 200...kids are expensive.
 
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