My Bruiser mods

[mettesse]

hi from the UK, It’s very interesting for me to see the number of people who change the engines in their trucks, I understand the quest for more power / torque, my question is what do you need the increase for?
I have a 4.2 turbo diesel from 94, loadsa miles on it and with a very small mod have all the power and toque I can play with. I get that a change from petrol to diesel or maybe the availability of said engines is a problem. It may be worth noting their are alleged several companies in Europe that “ fix” the pumps for gofaster types, well, this is what I did.
1) had the pump and injectors refurbished by a competent firm, not just new seals but valves, camplate the works, and same with the injectors
2) I have a fairly tame mechanic named Merlin ( fictitious name but justified)
3) same mechanic fabricated a very large intercooler and piped it into the induction system

We run standard boost, slight increase of fuel and let the magic work
My car is no racer, but smooth and powerful
The intercooler rad, the air con rad and oil cooler were then mounted in a type of cassette system in front of the water radiator under the front bonnet crossmember.

I’m told that this type engine is modified for use in marine applications to produce 1000bhp, albeit with special parts, ( I suppose pistons, cranks etc) and that the standard turbo (26) don’t like pressure incerease, an intercooler makes sense.
I have a hand fabricated extra large water radiator from brass / copper with the standard oil cooler inside (as standard) , the cooler is supplemented with an extra radiator behind the inter cooler
I’m happy with the results in that I tow a trailer with my off reader on it all up just over 3 tons all the way to Spain and back, 900 miles there 900 miles back no hassle or worry. ( up to now)
Here are some pics

 

[Mixelplix]

Looks fantastic!

 

[Heckraiser]

Do you have a front shot of the intercooler? The shape of the end tanks and where the pipes pass through the radiator support?

Thank you for sharing!

 

[mettesse]

Do you have a front shot of the intercooler? The shape of the end tanks and where the pipes pass through the radiator support?

Thank you for sharing!

Hello, sorry I don’t have any pics of the cooler, even if I take the front grill off it can’t be seen, but if it’s any use the connections are very low on the unit so the pipes run under the battery shelf on the intake side and a little higher on the “out” side, not very technical. It’s also very robust in that it takes the part of the support for the bonnet latch scuttle. It’s just that the standard of workmanship is very high. The “ bridge” with TURBO on it is just a support and was taken from the original manifold, looks good eh? As I said Merlin is an ace engineer, he has very high accreditation for diesel engineering and he is an 80 affectionado. Over the last 10 months he has rebuilt a ‘94 80 for a customer, recon everything, axels, auto box, ( he makes a double clutch assy, ) engine, starter, Altermater, the lot, body off repaint, it’s like a brand spanking new car, beautiful. This of course don’t help you, but I know you have some very innotive chaps across the pond who could sort you an inter cooler from scratch.
Having an 80 is a bit like grandads hammer, ( original, had it for 60 years, only had 3 new shafts an two new heads)
Everything can be altered or changed, here in Europe Mr Toyota must rub his hands together because spares ain’t cheap from him, but gladly most things are available which is a bonus. What I should also say is I have a complete 3inch diameter stainless exhaust made by a race car company, bespoke and a work of art, with only a tiny silencer to take the “ bark” out the exhaust noise. I think this helps.
Regards to all,

 

[Heckraiser]

Yes, definitely extra bling points for the "turbo" cross-piece. Well done.

 

[LouisianaRubicon]