Intercooler theory and sizing debate (1 Viewer)

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This is an awesome project! Any updates? I love the Volvo TGB trucks - hope to have one of my own some day - I also had thoughts of installing a diesel drivetrain too! Great minds think alike :)

-Phil
 
Hi,

I have not read all the post but that PWR barrel unit is just to small for a Turbo Diesel.

It maybe rated to enough HP but that has nothing to do with it's cooling ability.

The heat exchanger with it will not cope with a Diesel engine either.

Turbo Diesel's spend 80% of the time on boost making more heat doing so. Turbo Petrol 10% on boost. The intercooler is really designed to cope with a petrol not a diesel. Just think of the difference in percentage the intercooler has to deal with.
 
I run the PWR 4X10 barrel intercooler with a bosch pump and 2"X12X12 rad, it works much better than the air/air intercooler and to say that it is impossible to work is just wrong - it works great. Save designing and engineering my own water/air like the on here the PWR intercooler is the the most simple and effective way to intercool the 7X series. I have had both air/air on my truck and water/air and the water/air kicks butt over the air/air. I can't calculate the number on how efficient or bla bla bla, but I can vouch from actually installing and driving a truck with it installed. No speculation - just fact. I run 15PSI and my foot is to the mat most of the time.



Regards,
 
This is probably a stoopid question but......
Is there any chance of w2a intercooler leaking and killing the engine. I have a 13B-T with@250,000 km on it and would like to intercool it sometime in the future. I'm really interested in the w2a cause apart from being better at cooling the air and reducing pressure drop, i reckon it would fit better under the bonnet.

It may have been bought up earlier in this thread. I haven't had a chance to read the whole thing yet. So what are the chances of a leak in the intercooler damaging the engine?

Cheers,

Gav.
 
I have never heard of it happening, what about a turbo coming apart and throwing pieces into the engine?

Regards
 
lshobie said:
I run the PWR 4X10 barrel intercooler with a bosch pump and 2"X12X12 rad, it works much better than the air/air intercooler and to say that it is impossible to work is just wrong - it works great. Save designing and engineering my own water/air like the on here the PWR intercooler is the the most simple and effective way to intercool the 7X series. I have had both air/air on my truck and water/air and the water/air kicks butt over the air/air. I can't calculate the number on how efficient or bla bla bla, but I can vouch from actually installing and driving a truck with it installed. No speculation - just fact. I run 15PSI and my foot is to the mat most of the time.



Regards,
Click to expand...

Guess I know nothing then.

Wouldn't know what the inside of a PWR looks like.

100_6046.jpg


Or what pre and post air temps should look like on a Turbo Diesel well intercooled.

IMG_0001-13.jpg


Or the power gains to be had from been intercooled.

IMG-28.jpg


What are your pre and post temps and map (PSI) and power gains, apart from it's better?
 
Good to know. Do u have pics of your pwr set up? Did you have to cut the bonnet and install a scoop to make it fit? And lastly does the water pump come in a 24v option? I have looked at the pwr site but didn't see if they offered a 24v pump.

Cheers.
 
Guess I know nothing then too - I just use it on my truck and it works, must be imagining it.

EDIT sorry, like I said, nothing on paper about how much better it is - it just is. The results are from driving the truck - not from writing things on paper. I think practical results speak for themselves - or maybe I am just a retard.

The only thing I will be doing is dynoing it after I install my new tranny/transfer and ceramic coat the manifold and exhaust housing. I'll video tape it with temps/boost and results - thats the best I can do for you.
 
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lshobie said:
Guess I know nothing then too - I just use it on my truck and it works, must be imagining it.
Click to expand...

Don't get me wrong it will be beneficial but in my experience they do not suit turbo diesel well.

My point of view was not without experience.

PS: I have driven the ones on paper too, most people who intercool will tell you its better, it usually is too, but how much better is not quantified. Can it be better still.

There is very little real info out there on how well an intercooler works, they rate HP but that has little to do with it's cooling ability.
 
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matt.mcinnes said:
Don't get me wrong it will be beneficial but in my experience they do not suit turbo diesel well.

My point of view was not without experience as you seemed to suggest.
Click to expand...

Ok, so you have run the PWR on a 1HZ and know how it works, and compared the practical results to an a2a system on the same truck?

Boy, if my intercooler doesn't work and yours does I would certainly like to run yours on my truck. Not saying that yours doesn't work as it surely would - I would just love to see how much better it works because with the way mine works on my truck I don't need any improvement to be happy. My set up is the same as the denco kit I am pretty sure, but I use a large rad.

Saying something works or something doesn't work because of a theory can be right most of the time - but practical results speak for themselves. I am not selling intercoolers so I have nothing to gain by saying IT WORKS GREAT.

EDIT yes there would be better systems that could be "designed and made" but to make something marginally better for much more money/time and effort is false economy in my opinion. I bought this stuff for about 800 or less and everything is off the shelf. Works like a charm, and night and day from no intercooler to this, and better then the a2a type. I still have some mods to make, I need a bleeder on top of the barrel because I think there is still a bit of air in it - so it can only get better.
 
lshobie said:
Ok, so you have run the PWR on a 1HZ and know how it works, and compared the practical results to an a2a system on the same truck?

Boy, if my intercooler doesn't work and yours does I would certainly like to run yours on my truck. Not saying that yours doesn't work as it surely would - I would just love to see how much better it works because with the way mine works on my truck I don't need any improvement to be happy. My set up is the same as the denco kit I am pretty sure, but I use a large rad.

Saying something works or something doesn't work because of a theory can be right most of the time - but practical results speak for themselves. I am not selling intercoolers so I have nothing to gain by saying IT WORKS GREAT.

EDIT yes there would be better systems that could be "designed and made" but to make something marginally better for much more money/time and effort is false economy in my opinion. I bought this stuff for about 800 or less and everything is off the shelf. Works like a charm, and night and day from no intercooler to this, and better then the a2a type. I still have some mods to make, I need a bleeder on top of the barrel because I think there is still a bit of air in it - so it can only get better.
Click to expand...


Cant see anywhere I tried to sell an intercooler must have missed the link I posted.

As for replacing PWR's yes been there done that have the data. Never replaced an air to air so can't compare as yet, early next month not a problem as we are currently doing one, but not on a 1HZ, Nissan TD42 same size 4.2 straight 6.

As for something been marginally better without paper and testing your just poking a stick in the dark. Like anything you get what you pay for.

Regards Matt
 
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matt.mcinnes said:
Cant see anywhere I tried to sell an intercooler must have missed the link I posted.

As for replacing PWR's yes been there done that have the data. Never replaced an air to air so can't compare as yet, early next month not a problem as we are currently doing one.

As for something been marginally better without paper and testing your just poking a stick in the dark. Like anything you get what you pay for.

Regards Matt
Click to expand...

I never said you were selling them, I said that I had nothing to gain by saying it worked great.

Ya, just poking a stick in the dark, like a retard who can't drive a standard.

Have fun with your theories.

Louis
 
lshobie said:
Have fun with your theories.

Louis
Click to expand...

I can prove my theories.

But if works for you thats all that important as long as your happy with what you bought.

I was not having ago at you, as you did me, just offering my advice originally from my experience.
 
Mate, not having a go at you either, it just throws me off when someone takes a jab at something with no first hand experience on it - like a pwr on a 1HZ - like what denco sells. To say it won't work was wrong, it does - but just maybe not to your liking.

Regards
 
lshobie said:
Mate, not having a go at you either, it just throws me off when someone takes a jab at something with no first hand experience on it - like a pwr on a 1HZ - like what denco sells. To say it won't work was wrong, it does - but just maybe not to your liking.

Regards
Click to expand...

If you give PWR a call they don't recommend the that size for the 1HZ or the TD42 and that's PWR not me.

As for first hand experience it does not matter if it's Toyota or Nissan a straight six 4.2 Diesel is what it is. You just assumed I had no first hand experience with PWR coolers or replacing them. Don't get me wrong either they are a well made unit.

I stand by what I said in the 1st post, and I am not saying your intercooler did not improve performance. But without testing pre and post temps on sustained dyno time, you don't really know how well it improved and how much more room for improvement there is.

I think form memory which is not so good PWR recommend the 6x8 or it maybe the 6x10 for the 4.2 Turbo Diesel.
 
Please see the attached email from PWR - they do in fact recommend the 4X10 barrel type intercooler.

Don't have to call them - I emailed them before I installed the intercooler. I let the guys who have used them on models recommend what is best - or at least what they have that will fit the application. The 4X10 fit the best, as with most over the shelf intercoolers you can only buy what will fit - anything bigger would not go under the 7X series hood. I still plan on placing some thermocouples to check the inlet/outlet temps - just no time.

So, they actually do recommend that 4X10 intercooler. I don't theorize and make calculations, I don't have to because I don't custom fab things like intercoolers - I just buy what is recommended. Your intercooler sounds great, if you were closer I'd have you over for beer or whatever your poison is and I'd con you into building one of yours for me:)

Here is his email:

Dear Lewis,

Thanks for your enquiry.

For that HP we have a range of 4" barrel coolers which are ideal for your Landcruiser and will overcome Turbo Lag and make your engine run more efficiently.

As a rule of thumb the longer the barrel the better cooling you are going to get. Therefore it is good to check how much space you have for the application.

4"x6" barrel cooler - 290mm long
4"x8" barrel cooler - 349mm long
4"x10" barrel cooler - 395mm long

The kit comes with the following; Pump, Billet inline filler, Barrel cooler, small radiator and thermo fan. We find that the 4"x8" is the most popular one for land cruiser's. However some people are going for the 4"x10" if they have the room.

We also offer Aluminium Radiators and Oil coolers specifically designed for Landcruisers.

Please let me know if you have any further questions.

Thanks,

Zac
 
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I was told that the 6 inch was too big, someone in south america runs 2X 4X8's under the hood of their HDJ81 - no idea how well it works.

I made the enquiry through Enquiries@pwr.com.au
 
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