The official 1HDT Intercooler thread (1 Viewer)

[gbentink]

Hi, well, we did 11,500km and averaged 18.2L/100km towing a massive van.

A couple of things I learnt:

- dead stock 1HD-FTE in 100 series is up to 710C pre turbo - higher than I had thought and checked last week on another 100.
- I did the whole trip not going over 670C at any point, but I will tune a bit higher.
- my intercooler dropped that by 60 degree's
- my air intake temps never went above 60deg C - even at 28psi
- AFR's towing at 100km/h on flat were 27-30:1 typically at 12psi and EGT's 460C (pre turbo)
- My A750F gearbox (with valve body mod) needs more tweeks to handle 30psi long term (but it just so happens that this can be achieved electronically)
- going 1:1 (4th) up steep hills towing 4 tonne at 80+km/h is fun ....and a bit stressful. At one point loaded right up, 26psi at 1800rpm, grunting up this mountain (hill elsewhere in the world) and almighty bang occurred when the factory rubber boost hose exploded (it didnt just crack). Lucky I mapped fuel to 25psi and I didnt melt the engine with a sudden boost drop. I did a McGyver with braided fishing line and Sikaflex.....

Happy boosting, G

not questioning that it can be done but it will be interesting to see the temps and if it is mountainous then the resulting strain on the 373 tranny. i "think" it is an auto.

 

[Adam B]

- my air intake temps never went above 60deg C - even at 28psi

WOW! What ambient temp are we talking about?

At 5C ambient I had 90C post IC and at 15C ambient it was 100C post IC - all at only 20psi boost on long steep hills.

I really need to get my ass in gear with the bigger IC project......

 

[ForealBoreal]

Adam I think you should go with a big air to air front mount.
I have been reading that on longer stuff (over a min at full load) that air to air is superior

 

[brumbyrunner]

Hi, well, we did 11,500km and averaged 18.2L/100km towing a massive van.

A couple of things I learnt:

- dead stock 1HD-FTE in 100 series is up to 710C pre turbo - higher than I had thought and checked last week on another 100.
- I did the whole trip not going over 670C at any point, but I will tune a bit higher.
- my intercooler dropped that by 60 degree's
- my air intake temps never went above 60deg C - even at 28psi
- AFR's towing at 100km/h on flat were 27-30:1 typically at 12psi and EGT's 460C (pre turbo)
- My A750F gearbox (with valve body mod) needs more tweeks to handle 30psi long term (but it just so happens that this can be achieved electronically)
- going 1:1 (4th) up steep hills towing 4 tonne at 80+km/h is fun ....and a bit stressful.

Hi Greame, I've been waiting to see how your trip went. Couple of quick questions...

- Did you measure EGTs post turbo as well? Most of us have our probes post turbo (just because it's easier) and it would be interesting to compare your temp drops across the turbo.
- Did you record ambient temps against your intercooler temps to measure temp drop?

 

[Trock]

I'm going to have a go at fabbing my own pipework for my front mounted intercooler on my HDJ81 which I want to install in preparation for the GTurbo that I'll be hopefully ordering in the coming weeks..

Do I have to use stainless pipe or is mild steel also ok as long as I get it galvanised? I'm sure there must be some condensation going on it there so don't want to make an error when picking the right material for the job.. If it has to be stainless then so be it.

My plan is to do all the cutting and routing, tape the pieces together and then take them to a welding shop and make sure it's properly welded. I'm hoping to get the inlet manifold adapter from a local company that makes kits for the 1HD series..

Also I was wondering if anyone could tell me what the diameter of the outlet at the turbo is? Sure would save me some time removing the air cleaner to get the measurement to get the right silicone joint..

 

[Tapage]

Also I was wondering if anyone could tell me what the diameter of the outlet at the turbo is?

2" as factory is ..

 

[Tapage]

though should update this thread with my IC

I made a shroud ( kinda ) on the IC ( not included in the above pic )

 

[crushers]

that ended up looking familar and pretty good ...

 

[Trock]

2" as factory is ..

Thanks Tapage..

The inlet and outlet pipes on my cooler are 57mm (2 1/4inch) should I stick with 2 inch ducting as per the turbo outlet or go up to 2 1/4? I seem to remember reading somewhere that it's adviseable to go up to 2.5 inch pipes when boost pressure is over 18psi.. could be wrong though...

Edit: I've been advised to use 2inch pipe from the turbo to the cooler and 2.5 from the cooler to the inlet manifold - apparently it maintains the air velocity better with the smaller diameter pipe while the air is still hot.. sound right?

 

[Trock]

Can anyone confirm whether the pipework suggested in the post above will be the right move for a 1HD-FT? I'd really like to get the ball rolling on this and buy some materials.. thanks guys

 

[Trock]

I just called to order the inlet manifold adapter and it turns out is is also 2" so I'm just going to go with 2" pipe throughout seeing as the turbo outlet is the same diameter.. I'm no expert but it would seem pretty pointless to use a larger pipe and have it constricted at both ends...

 

[IanB]

I would expect the volume of the cooled air (post intercooler) to be less than that of the hot air (pre-intercooler), so if anything I would expect the opposite to be true.

 

[Trock]

Thanks Ian, I'm back to the drawing board however as the supplier only has manifold adapters for the 1HD-T and not the FT..

Going to try and get an engineering shop to make one up for me..

 

[IanB]

Thanks Ian, I'm back to the drawing board however as the supplier only has manifold adapters for the 1HD-T and not the FT..

Going to try and get an engineering shop to make one up for me..

What supplier was this, how much, link, etc? Could help some of us 1HD-T guys out.

 

[Trock]

It's a company called Cirrus intercoolers here in South Africa Cruiser 80 &100 Series they actually make a bolt on kit for the HD series motors which I would go for but the rubber type pipework is only rated to 17psi so would be pretty pointless when running one of Graeme's turbos. I want to avoid having to do this mod twice..

They only have the 1HD-T adapter in stock at the moment which is about $50.. It has actually changed in design from the one in the picture which is of a very early type - the one now is a cast aluminium unit. Also as you can see the the motor in the pic is a HD-FT, Cirrus in turn have a supplier who laser cuts another adapter so that the HD-T adapter fits.. This is the part they don't have stock of at the moment and they need to place large orders for these which the current demand doesn't call for..

I'd love to just bolt the kit on but really don't want to blow the pipes..

 

[gbentink]

The temps coming out of the turbo affect the service temp of the rubber hoses. So, its not the post intercooler side to worry about (pressure rating wise), its the pre intercooler. If you could change the pre intercooler pipes you may be able to raise the boost safely a bit higher 20-22 psi (then you are getting somewhere). The kit looks nice for sure, but who wants to be limited to 17psi.... The answer is... some people!

There is still a point to using a Gturbo if you want 17psi by the way (or even 14psi) - the torque below 2000rpm is entirely different. What you would get without an intercooler at 2000rpm, you will get at 1400rpm with a Gturbo, intercooler and tune.

Although I market high performance and high boost, I have a solution for almost every situation. So; 17psi you want with kick but bottom end torque - no problem

It's a company called Cirrus intercoolers here in South Africa Cruiser 80 &100 Series they actually make a bolt on kit for the HD series motors which I would go for but the rubber type pipework is only rated to 17psi so would be pretty pointless when running one of Graeme's turbos. I want to avoid having to do this mod twice..

They only have the 1HD-T adapter in stock at the moment which is about $50.. It has actually changed in design from the one in the picture which is of a very early type - the one now is a cast aluminium unit. Also as you can see the the motor in the pic is a HD-FT, Cirrus in turn have a supplier who laser cuts another adapter so that the HD-T adapter fits.. This is the part they don't have stock of at the moment and they need to place large orders for these which the current demand doesn't call for..

I'd love to just bolt the kit on but really don't want to blow the pipes..

 

[Trock]

Thanks for the response Graeme, some good useable info..

I'm keen to go with a unit in the 22-24 Psi range so am going to steer clear of the kit.. Besides I've already got a 230x450x65mm cooler that I just need to plumb. I can save quite a bit by doing this and would rather put it towards the turbo to try and maximise the overall value in terms of performance..

Would 2 inch piping be sufficient?

 

[Douglas S]

That Cirrus kit is very tempting. Doesn't look like it's too expensive either, even after factoring in shipping costs.

 

[jamcorse]

I have an ASE front mount intercooler from Australia with silicone and aluminum pipe work and a GTurbo running at 20psi. I blew off a few pipes including the one for the ic boost valve. Tightening the clamps and generally better securing all of the pipe work seems to have done the trick. I've just done a 1500km round trip here in Tanzania and it has held up fine. So if you are struggling to make it work without silicone joints and bends, try the silicone, it seems to be ok for me!

 

[gatier]

Hey, could you please post some pictures of the IC fitted in? Did you need to do any modifications/ trimming to get it in there? Do you run AC and tranny cooler?
thanks

I have an ASE front mount intercooler from Australia with silicone and aluminum pipe work and a GTurbo running at 20psi. I blew off a few pipes including the one for the ic boost valve. Tightening the clamps and generally better securing all of the pipe work seems to have done the trick. I've just done a 1500km round trip here in Tanzania and it has held up fine. So if you are struggling to make it work without silicone joints and bends, try the silicone, it seems to be ok for me!