Intercooler kit for SC- gauging interest

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Air flow doesn't seem to be restricted through the core (there is a small clearance on the DS side of the core between the IC and the valve cover, the PS sits over a void above the exhaust manifold). All top mount ICs I've seen have a sealed air diverter to force air through the core. I was amazed at how easily air flows through the core even when just blowing on it. You shouldn't lose pressure through the IC as it's designed to provide more than adequate flow for the motor. If the flow was restricted, it would create an increase in pressure on the SC side and a drop in pressure on the intake side. That would be a poor design IMO. Obviously, I haven't tested this, but I believe in the numbers that the engineer I worked on this project with provided as this is his area of expertise.
 
thanks for the info
 
So I spoke to a buddy of mine here about gathering some non-scientific "data" on the intercooler and smaller pulley performance gains.

He has a SC'd '97 with ARB front, Kaymar rear, ARB roof rack, 4.88s & BFG 35s. Mine is a SC'd '97 with ARB front, Kaymar rear (with dual swingouts including 37" spare), Slee sliders, longranger aux tank, AO drawers loaded to the gills, 4.88s & 37" trxus.

We are going to go head to head out of a traffic light after we have gotten the vehicles up to temperature. On paper, he should beat me hands down as I weigh more and he has smaller tires with the same gearing. We will mat it out of the light and let the trannies do their thing as they are also the same. We will get some video when this takes place. If nothing else, it should be entertaining.
:cheers:
Nick
 
Did you get a chance to run it with the stock pulley or did you go straight to the smaller one? Looks like it turned out really nice. I am not sure what I'm going to do about getting fresh air to it, as I can't decide if I like the look of a scoop on the hood or not...I think I'll try to take some temps before and after the cooler to see what it does just plugging it inline. Seems like it should provide some cooling effect just by being there vs the stock TRD setup.
 
I threw the smaller pulley on before I installed the IC. I don't think you will get cooling without the scoop.

This past weekend I ran over to Delta and towed a boat back. This takes me over McClure Pass which I drive several times a year so I know how the cruiser normally feels on it. On the Carbondale side without the boat, it pulled easily to the top with power to spare and didn't get hot. From the Delta side on the way back with the boat (16' boat with big outboard and fairly lg trailer), it pulled right to the top. It got warmer (210-212 IIRC), but pulling my camper without the IC and pulley, I normally drop AC (>217) while winding it in high RPMs of 2nd gear.

A couple things to note:

1. I think I need something to keep the bugs out. It was a buggy evening and I have a bunch of bug carcasses on top of the IC.
2. I forgot about my windshile washer nozzles. I didn't want to put the Toyota ones back in as the new holes (keywayesque) would be a PITA. So I ordered up these (Amazon.com: Dorman 47137 Windshield Washer Nozzle Kit: Automotive they go into a round hole. I also like the fact they they mist as opposed to the streams on the OEM ones.

Guys who ordered, The ICs are supposed to ship from the manufacturer on Friday so I will have the kits ready next week. Unfortunately for you (fortunately for me;)), I'm leaving for CM12 on Wednesday. If anyone is going to be at CM12, I can probably arrange for my wife to deliver when she comes down late Thursday or Friday. Obviously, if I get them prior to my departure, I will invoice the balance and ship out!
:cheers:
Nick
 
Looks like just what the doctor ordered. Has to help! My 97' LX450 is in the body shop now after a front end collision - so have to get a new hood anyway! Might as well put some holes in it to help it run cooler with an intercooler if possible.

Definitely up for one of these intercoolers. Let me know how to proceed.

Warming up in AZ . . . 105'F already last weekend.
 
I picked up my kit at CruiseMoab :-)

Now I just need to find time to start work.


image-2019735091.webp

Sent from my iPhone using IH8MUD
image-2019735091.webp
 
I would also love to see some real data on Temp before and after. regular pulley and small pulley.

Somebody do it:)
 
That is my plan. I am currently gathering data for S/C with stock hood. Next mod will be hood vents. Then hood scoop with inter cooler. Finally smaller pulley.

Be advised, this will not be a one day report. I will do the mods one at a time and then drive a variety of conditions and loads to try to collect real world data over time.

Please stand by as this is not on the top of my list (though close :-). I will post up data along the way. Stay tuned.

Sent from my iPhone using IH8MUD
 
boydmick said:
That is my plan. I am currently gathering data for S/C with stock hood. Next mod will be hood vents. Then hood scoop with inter cooler. Finally smaller pulley.

Be advised, this will not be a one day report. I will do the mods one at a time and then drive a variety of conditions and loads to try to collect real world data over time.

Please stand by as this is not on the top of my list (though close :-). I will post up data along the way. Stay tuned.

Sent from my iPhone using IH8MUD
Click to expand...

Really interested to see what your results are. Thanks for doing this.
 
2nd Buy for InterCoolers?

Nick,
Is there a list forming for a 2nd production run for those of us that missed the first round of these intercooler/flange/diverter kits? :bounce: Father's Day is coming! Unfortunately so is 110'F.
Randy
 
Hey Nick,

I paid the paypal invoice you sent me last week and sent you a couple messages with no response. Did u ship my kit? Were u able to include the air diverter? Please let me know.

Thanks,

Adam
 
Adam,
I'm still waiting on the diverters from the sheet metal shop. If you'd like, I can send the rest of the stuff separately.


Guys,
Regarding a second run, I'm just going to do one offs. There isn't worthwile savings in the production considering they are small groups. It would have to be 10+ to make any noticeable difference.

Also, my machinist and I both took a bath on the first run. I really thought we could get these out for $700, but in time, materials, and shop time, we came out way behind. That's not considering the R&D for my initial kit either.

Unfortunately going forward, the kits are going to $900. That will include the air diverter as it works very well for this application.



On a positive note, pulling my camper to and from Moab with the new setup was awesome!:D Hills where I would normally drop to 65-70 winding it out, I approached with the cruise set at 80. Once I hit the hill, my speed would drop to ~75, drop a gear, and climb right back up to 80.:steer: Also, I wasn't borderline on temps and losing the AC. Pleaes keep in mind that I have done a bunch as far as cooling efforts go as well (14" pusher fan, 24k clutch, vents, yada yada). On the way back to Colorado, I was rocking at about 85 MPH. Also, my camper is small, but it is HEAVY. Long story short, the drive to/from Moab with my camper is one that I am familiar with. With the intercooler kit and 2.8" pulley being the only difference, it was NIGHT and DAY!
:cheers:
Nick
 
Looking at alternatives to a hood scoop...

Since I'm not sure my wife will be okay with me chopping a hole in the hood to mount a WRX scoop, I've been thinking of other ways to get air to the IC. One of things I thought might be doable and cool looking is something like the fake hood vent on the front of the FJ cruiser hood, but just above the grill on the flatter part of the hood. Thoughts? I'm doing this brainstorming to keep myself occupied out here on deployment so I can't measure anything, just thinking of possibilities. It seems like this would get a good amount of direct airflow. Obviously some sheetmetal work to get it channeled up to the IC would be in order, but it wouldn't be noticeable from the drivers seat and could be a fairly easy way to get air up there.
 
Atoyot1031 said:
Looking at the actual size of the hole and seeing all of the small scoops used in the DR for top mount ICs, I think you could get away with a low profile offset small scoop like the old nissan z or something.
Click to expand...

I thought about that, but wonder whether the airflow would be enough. It seems like with a setup similar to the one on the FJ, by the time you channeled down to the actual IC you'd have quite a bit of airflow going through it.
 
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