Tapage
Club 4X4 Panamá
dude ... please another shot of your engine bay please .. I should print it and show to Tencha, maybe she learn how she need to looks always .. 
Home Brew Intercooler (1 Viewer)
- Thread starter matt.mcinnes
- Start date
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Popped down to Awill4x4 today for a little Tig time.
Tks Andrew and hope you Enjoyed the ride
Now I can measure pre and post intercooler, once connected up.. Also braced the rear intercooler radiator.
Yes, I enjoyed the ride very much Matt, it certainly surprised me just how quick it really is, it justs gets up and boogies very nicely.
It'll be great to get some accurate temp and psi figures pre and post intercooler but seeing how cool it was after you fanging it down the road a few times I think it's working very well indeed.
We've just got to convince Darren now
Regards Andrew.
matt.mcinnes
2F-ETI
- Thread starter
- #144
The one on the left is a 1/4BSP Allen Cap grub screw which will be replaced by a 1/4bsp hose tail connected to an external 2 Bar MAP sensor.
The Wolf V500 can then data log this side by side on the same graph with the internal MAP sensor.
The second is a A/C Delco SCR-12V-3 air temp sensor, the same as the post intercooler sensor all ready fitted.
This then too can be data logged real time.
which will be replaced by a 1/4bsp hose tail connected to an external 2 Bar MAP sensor.The Wolf V500 can then data log this side by side on the same graph with the internal MAP sensor.
The second is a A/C Delco SCR-12V-3 air temp sensor, the same as the post intercooler sensor all ready fitted.
This then too can be data logged real time.
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matt.mcinnes
2F-ETI
- Thread starter
- #145
Ok both temp sensors are now operational but my lap tops battery is shot so I can only connect in the garage. Marin will be up this eveing after work with his for some real time data logging.
Early signs however are after a run out and back to the garage are good. The Per intercooler temp is 51c Post 26c ambient 13c
Early signs however are after a run out and back to the garage are good. The Per intercooler temp is 51c Post 26c ambient 13c
matt.mcinnes
2F-ETI
- Thread starter
- #146
I've been testing NOT Hooning
Pre inter cooler cruising temp is 50C/122F
Full boost rises to 82C/180F
Post inter cooler cruising temp is 25C/77F
Full boost rises to 31C/87F
Note the heat rise was only on the second run first run showed a 1C drop post intercooler. After 5 runs no post intercooler temp over 31C/87F
Ambient 12C/53.5F
Calculated Temps are spot on too
The photo of the graph below shows 2nd to 3rd to 4th
The Red line in the top graph is Pre intercooler temp, I am using the external map sensor input to read it so the scale is wrong, you have to multiply it by 1.82
Yellow is correct, Post intercooler. hope that makes sense.
Pre inter cooler cruising temp is 50C/122F
Full boost rises to 82C/180F
Post inter cooler cruising temp is 25C/77F
Full boost rises to 31C/87F
Note the heat rise was only on the second run first run showed a 1C drop post intercooler. After 5 runs no post intercooler temp over 31C/87F
Ambient 12C/53.5F
Calculated Temps are spot on too
The photo of the graph below shows 2nd to 3rd to 4th
The Red line in the top graph is Pre intercooler temp, I am using the external map sensor input to read it so the scale is wrong, you have to multiply it by 1.82
Yellow is correct, Post intercooler. hope that makes sense.
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Tapage
Club 4X4 Panamá
Damn .. you are droping huge range ºC thought your ambient temp helps a lot .. but the air that it's getting your intake it's freaking cold !
So your intercooler effectiveness = actual temp drop/total temp difference
Cruising.
(50-25)/(50-12)
= 66%
Giving it death.
(82-31)/(82-12)
= 73%
That's a very good result. Do you know what your cooling water temp levels out to?
Cruising.
(50-25)/(50-12)
= 66%
Giving it death.
(82-31)/(82-12)
= 73%
That's a very good result. Do you know what your cooling water temp levels out to?
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matt.mcinnes
2F-ETI
- Thread starter
- #149
No idea what the intercooler water temp rises too.
Later runs saw the intake temp drop to 23C and max out at full boost 29C as the night air cooled even more. But 29C is short lived.
A water wetter should see the above improve a little too.
I think the more boost the more efficient it will become as it soaks more heat up.
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matt.mcinnes
2F-ETI
- Thread starter
- #150
Well just one job left to do, something that should have been thought about at the start but as we all know you always miss the simplest things 
Going to drill and fit a small bleed nipple to one end of each of the end caps to remove the air from the the system this should help with the heat exchange too. Then it will be even better
The Snorkel should also see intake temps drop closer to ambient as it's dam hot under the bonnet.
Going to drill and fit a small bleed nipple to one end of each of the end caps to remove the air from the the system this should help with the heat exchange too. Then it will be even better
The Snorkel should also see intake temps drop closer to ambient as it's dam hot under the bonnet.
Well just one job left to do, something that should have been thought about at the start but as we all know you always miss the simplest things
Going to drill and fit a small bleed nipple to one end of each of the end caps to remove the air from the the system this should help with the heat exchange too. Then it will be even better
Damn, why didn't I think of that.
matt.mcinnes
2F-ETI
- Thread starter
- #152
Next week will see the final testing if the intercooler, Pre and Post pressure drop. This has been bench tested and those results were very good but, I am a firm beliver in real time testing.
matt.mcinnes
2F-ETI
- Thread starter
- #153
Just a little up date on the new intercooler for a straight 6 diesel.
You can see the overall size has been reduced from my original design
The Air in and out is slightly different too leading to a different layout of the cores.
Along with the new improved end caps which are smaller too.
You can see the overall size has been reduced from my original design
The Air in and out is slightly different too leading to a different layout of the cores.
Along with the new improved end caps which are smaller too.
matt.mcinnes
2F-ETI
- Thread starter
- #154
Made a test piece up with the help of Awill4x4, I always new we had no problem with seals but now its official Tks to Awill4x4. Reverse tested with air.
The core was pressurized with air to 100PSI after an outer sleeve was welded over the test core and inner sleeve.
No bubbles from the water channels the O Rings are good.
The core was pressurized with air to 100PSI after an outer sleeve was welded over the test core and inner sleeve.
No bubbles from the water channels the O Rings are good.
just out of curiosity what are cores worth these days as i couldnt find any on ebay but want to build an intercooler for my hj75 turboed 2h im trying to build at lowest possible cost as the missus hates me spending money on the ute
matt.mcinnes
2F-ETI
- Thread starter
- #156
Last lot I looked at on Ebay were $250 for a set of 4
guess ill just have to save up then but wether its worth it or not is another matter as i fitted my egt sensor from ThermoGuard Instruments to the inlet manifold pipe as it exits the turbo today and all i got was 90 degrees at 9psi @ 2700rpm i can hold max boost for ages on the highway as the poor old 2h struggles to sit on 100kmh held flat even though its only done about 15000 km since rebuild mabe ill try the fuel delivery screw and see if i cant get a bit more out of her https://forum.ih8mud.com/diesel-tech-24-volts-systems/90288-fuel-delivery-screw.html
matt.mcinnes
2F-ETI
- Thread starter
- #158
90 degrees is about right for 9psi I have about the same, after my intercooler it's down to below 30 degrees. Ambient at around 12 will be better once I have a snorkle back on too.
But a rebuilt 2H should sit on a 100kmh in 4th without a turbo on the freeway, The Troopy's I have had with far more k's on the clock would bo that.
Rule of thumb is for evey 1 degree you can take from the intake temp you take 1 degree for you exhauste temp.
I would expect a Turbo 2H to purr all day at 100kmh after a rebuild.
Also an itercooler like mine cost me all up around $800Aus the water pump alone is a quater of the cost, I was lucky and picked my 4 cores up for $50US, cost more to ship them and thats if you can machine and weld all the parts cheaply as I could, you should still be in under $1000Aus, to have one made, well I was quoted as the first post says $3000 and that was only for 3 cores and I doubt it would have fitted or been as well made as mine, it maybe as the post says home brew but it a dam fine one
Another thing to think about, Air to Air is far cheaper and works well for road aplications such as freeway driving and towing, I built mine with more off road in mind low range, low speeds, high revs where an Air to Air is not effective. Horses for corses
matt.mcinnes
2F-ETI
- Thread starter
- #159
The generic end caps are now complete so if any one want's any feel free to PM me I had a 100 made to suit a dash 8 fitting.
Cost $30 each plus shipping
The support ring and O-ring are $5 a set.
Generic tubes are also available at $50 each for housing the Laminova cores used in my intercooler. Link to core specs
End plates can be made to order.
Cost $30 each plus shipping
The support ring and O-ring are $5 a set.
Generic tubes are also available at $50 each for housing the Laminova cores used in my intercooler. Link to core specs
End plates can be made to order.
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matt.mcinnes
2F-ETI
- Thread starter
- #160
I sold 5 kits already
