The official 1HDT Intercooler thread

[TuffMudder]

Finally decided. Went with the cxracing bar and plate for added durability given my planned use. Ordered today and will have tubing made at install. I think I'll be happy with the results

Cxracing 25x12x3 Bar and Fin Intercooler

Adapter

Total is $274 so after tubing I'll still be saving $1000 over the price and I honestly don't think this will underfperform the $1700 PDI significantly enough to even come close to justifying that extra cost.

I'll post final price and pics when it's finished, though that will be 3 or 4 weeks from now as I won't even have the LC until the middle of next week (it was loaded on the transport yesterday)

 

[wedgetail]

Has anyone tried/thought of using the TMIC core off a vdj79 as the basis for a FMIC? I’ve bit the bullet and bought one for $50. My only fear is that it’a height will make it difficult - measures 615x400x75 (24”x16”x3”) but I’ll be putting it in a 105 not an 80. The main attraction to me (other than price) was I know it’s a top quality product. Worst case I can probably sell it for a profit. Can’t beat opportunistic holiday purchases - jut have to fit it into the suitcase along with the new HD CI clutch kit I picked up for $150!

They aren’t known as the beat ICs in the stock application but I reckon that’s coz they’re an TM A2A, not because of poor thermal effeciency.

Has anyone else fitted a FMIC 400mm high in a 100/105? Manual so no trans cooler to worry about and no winch plans either.

 

[mudgudgeon]

Where are inlet and outlets?
The bonnet latch limits the amount of height available, it may push the core pretty low

 

[wedgetail]

Well I’m temporarily 105less (not for long - my wife is not amused by my brother’s hj60) but I remember looking in that region with a mate and we were both thinking how much space there was. Yeah the latch would be the limiter for height but not that low... picked up my 79 core will have another good look at it. Has two inlets so have options on which to use

 

[wedgetail]

Ok just had a look - would be best flow wise to use the ports diagonally Opposite but might be easier to use the same ends. I thought it came with adapters but no, so I’ve got even more fab’ing to do. I guess it means I can chose pipe diameter on them rather than adapt. I’m planning on mapping it out and buying all components from Donaldson - prices seem pretty good. Will be going MIGed alumized steel and silicone hose and T bolt clamps.

So pipe diameter - 2” vs 2.5” vs 3”... I know it was covered earlier In this mammoth thread but I reckon there wasn’t a clear conclusion. But it seems Mud at least you reckon 2.5” is the go?

It’s a tube and fin as you can see - the photo is poor it actually has another round of smaller fins inside the tubes - id say heat transfer will be pretty good same with flow. And of course quality is flawless..

 

[DarkHorse1HDT]

Is this thing on...?

Anyone have any thoughts on this:
AF90-1000 - Aluminium Intercooler 600x300x76mm with 3" Inlet/Outlets - Raw - Intercoolers - Turbo Accessories - Turbo & Nitrous System Accessories - Aeroflow Performance
or even cheaper in powdercoated black:
Aeroflow AF90-1000BLK Front Mount Intercooler (Black) 600x300x76mm

Cheap and basic tube'n'fin, but 600x300x76, has 3" in/out, tapered end tanks... and 1/6th the price of a much prettier Plazmaman:
Plazmaman Intercooler 600x300x76 Swept Back Raw
Angled in/outs, claiming 20% more flow?

It's not a realistic comparison, as I can't afford a $1200 IC, but interested in what people think of the differences.

 

[bjowett]

For the DIY liquid crowd. Toyota/Lexus offer some nicely sized heat exchangers that are used for turbocharger or inverter cooling. The largest is the unit from the NX200T, the core is 27.5" (700mm) wide x 17" (430mm) tall. There are smaller units for the various hybrid inverter cooling. They might also be a good source for circulating pumps and expansion/reservoirs.

 

[mudgudgeon]

Is this thing on...?

Anyone have any thoughts on this:
AF90-1000 - Aluminium Intercooler 600x300x76mm with 3" Inlet/Outlets - Raw - Intercoolers - Turbo Accessories - Turbo & Nitrous System Accessories - Aeroflow Performance
or even cheaper in powdercoated black:
Aeroflow AF90-1000BLK Front Mount Intercooler (Black) 600x300x76mm

Cheap and basic tube'n'fin, but 600x300x76, has 3" in/out, tapered end tanks... and 1/6th the price of a much prettier Plazmaman:
Plazmaman Intercooler 600x300x76 Swept Back Raw
Angled in/outs, claiming 20% more flow?

It's not a realistic comparison, as I can't afford a $1200 IC, but interested in what people think of the differences.

A raw aluminium core will shed heat faster than a powder coated one.

 

[DarkHorse1HDT]

A raw aluminium core will shed heat faster than a powder coated one.

$25 quicker?

Yeah, I figured that. Will blend in with the chrome of the grille/headlights well enough too.

Thoughts on the unit itself?

 

[TheMU]

My PDI intercooler came is yesterday. Will be installing soon after powdercoating the piping.

Will be installe on a 1990 1HDT HDJ81 Auto.

PDI Intercooler unboxing

• TheMU
• Aug 4, 2018

PDI Intercooler unboxing

• TheMU
• Aug 4, 2018

PDI Intercooler unboxing

• TheMU
• Aug 4, 2018

PDI Intercooler unboxing

• TheMU
• Aug 4, 2018

PDI Intercooler unboxing

• TheMU
• Aug 4, 2018

 

[Loober]

sexy, it comes with a condenser as well?

 

[TheMU]

Thats the Auto Transmission Cooler..
Its Yuge!

 

[Loober]

I have the PDI kit on my 70 and very pleased with performance and construction, good choice

 

[Neil826]

Is this thing on...?

Anyone have any thoughts on this:
AF90-1000 - Aluminium Intercooler 600x300x76mm with 3" Inlet/Outlets - Raw - Intercoolers - Turbo Accessories - Turbo & Nitrous System Accessories - Aeroflow Performance
or even cheaper in powdercoated black:
Aeroflow AF90-1000BLK Front Mount Intercooler (Black) 600x300x76mm

Cheap and basic tube'n'fin, but 600x300x76, has 3" in/out, tapered end tanks... and 1/6th the price of a much prettier Plazmaman:
Plazmaman Intercooler 600x300x76 Swept Back Raw
Angled in/outs, claiming 20% more flow?

It's not a realistic comparison, as I can't afford a $1200 IC, but interested in what people think of the differences.

They ballon out with more than 20psi boost lol.
Cheap china bar and plate cooler is much better

 

[surfari-LC80]

So it took 4 years but is finally done and in the testing phase.
Here are pictures of it now:

 

[Gun Runner 5]

Latest product from Odd Iron Off Road.

 

[mudgudgeon]

So it took 4 years but is finally done and in the testing phase.
Here are pictures of it now:

Pretty serious bit of fabrication there, got any progress shots?

 

[surfari-LC80]

Pretty serious bit of fabrication there, got any progress shots?

1st version of the inlet and outlet. warped during welding and leaked so it is scrapped.

In progress pictures of the new hotness:

The intake flange is a cut down of a china copy PDI adapter off ebay.

the details:
Six 39.5mmDia 198.2mm Long Laminova cores
frozen boost type 118 heat exchanger
Jabsco water pump model 50840-0012 cyclone low pressure.
a cut up and re welded on of these: Water to Air Ice Box Reservoir
the whole thing holds about 9 liters of water.
the cycle is reservoir to pump, pump to intercooler in to intercooler out to type 118 HE, type 118 to reservoir.

Turbo is a Gturbo Grunter stage 1 or 2 from 2012 I think, cant really remember. A442F fully hydraulic transmission upgraded with a nomad stage 1 valve body. airbox is a cut up and customized 1fz airbox with a BMC airfilter. the fuel pump is stock aside from a few turns of the aneroid pin and main fuel screw. injectors are stock as well.

Im using prosport digital gauges for now and my figures may not be accurate, be that as it may the figures I got so far:

RPM: 2500 to 2800
KPH: 120
Boost: 28 psi
EGT: 1050F
Intercooler In: 295F (gauge peaked at 300F)
Intercooler Out: 148F to 152F
Ambient air temp: 87F

using this basic formula of effectiveness = (charge air into IC – charge air out IC)/(charge air into IC – ambient air) it gets around 72% to 74% effective heat exchange after 2 hours of driving.

still need to tune fuel pump. AFR peaked at 27.5:1.

 

[mudgudgeon]

Cool.
There was a whole bunch of laminova cored intercoolers being built a few years back.

 

[cody c]

So it took 4 years but is finally done and in the testing phase.
Here are pictures of it now:

You gotta tell us the details of the milled turbo diesel logo on top of her. That looks too good.