The official 1HDT Intercooler thread (7 Viewers)

[surfari-LC80]

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

Yep, one of them is mine waaaay back on page 16. started out with a block o' aluminum and a lot of optimism.

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

the milled logo on top is based on the original side decals I got from AUS. scanned, traced then scaled down a wee bit then converted to .dwg using sketchup. took about 24 hrs on the 3 axis cnc for the 1st one. the logo will be incorporated into the top of the intercooler on my next version of the it so it will look one piece and have no visible welds.

 

[cody c]

Wow, thats alot of time to cut, looks really good though.

 

[wedgetail]

These in are my build thread but I'll put them here as they're very on topic. I have finished the install of the 600x300x76 FMIC into my 105. There was a lot of fabbing but no (pretty much) cutting of the body or grill.

I did fab them up with shroud in place (well the altered FZJ one - still looking for an HZJ one) so it clears everything, just...

Vac pump plate mount

lift point mount

offside mount off body mount

nearside mount off body mount

Feels really nice and solid although seems to flex where it needs to. Just got to sort the filter housing out

 

[franzugan]

Upgrading my old Isuzu intercooler with a new 450x300

 

[franzugan]

All setup and ready for testing!

 

[Echelon]

All setup and ready for testing!

Did you build a custom adapter to connect to the intake?

 

[Dilspec]

Tremendous amount of great information here. With that said, I am between a Safari kit or the Cross Country top mount. Anyone know a US or Canadian vendor that has a a connect with Safari? I am curious how much it is.

 

[wardharris]

Tremendous amount of great information here. With that said, I am between a Safari kit or the Cross Country top mount. Anyone know a US or Canadian vendor that has a a connect with Safari? I am curious how much it is.

Cruiser Brothers represents Safari Performance Products via Terrain Tamer. Contact Georg Esterer at georg@cruiserbrothers.com, PM @orangefj45 or call 1-209-425-4970.

He specializes in diesel upgrades/swaps and has provided a range of Safari products not otherwise seen here, including intercoolers, turbos, etc.

 

[Dilspec]

Thank you!

 

[tmarx]

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

Got any pics ?

 

[TurboDennis]

Quick question:
If you have an automatic tranny specific radiator that has transmission cooling section on the bottom, and lets say that you are not using that section for whatever reason (5spd conversion, separate tranny cooler, etc), would it be possible to use that section as a radiator for water-to-air intercooler setup? Seems like an ideal solution to me - no plumbing of air hoses, no fabricating, factory look, powerful fan blowing on it all the time, etc.

 

[IanB]

Quick question:
If you have an automatic tranny specific radiator that has transmission cooling section on the bottom, and lets say that you are not using that section for whatever reason (5spd conversion, separate tranny cooler, etc), would it be possible to use that section as a radiator for water-to-air intercooler setup? Seems like an ideal solution to me - no plumbing of air hoses, no fabricating, factory look, powerful fan blowing on it all the time, etc.

I don't think it will do great at that, as it's not really an air to water cooler, but rather a water to water cooler, where the coolant temp is the coolest your intercooler water will be able to achieve before taking another pass through the intercooler core.

 

[TurboDennis]

I don't think it will do great at that, as it's not really an air to water cooler, but rather a water to water cooler, where the coolant temp is the coolest your intercooler water will be able to achieve before taking another pass through the intercooler core.

I dont believe that would be the case. The tranny cooler section of the main radiator is separate from the engine coolant section. It does share a "wall" inside the radiator and will soak in some heat from that, but the intercooler water going through there will definetly be able to get much cooler than the engine coolant.

 

[FJRanger]

I don't think it will do great at that, as it's not really an air to water cooler, but rather a water to water cooler, where the coolant temp is the coolest your intercooler water will be able to achieve before taking another pass through the intercooler core.

I've to agree with Ian on this. Plus the thermal efficiency of the that "cooler" isn't the greatest. From my understand it was more of a design to get the transmission fluid up to operating temperatures. The cooling aspect is only a tiny portion of it and isn't great, I know this all too well from first hand experience. I will tell you outright it is not set up to handle a consistent high heat load. One reason why all the NA 80s came equipped with an auxiliary trans cooler.

 

[IanB]

In-rad transmission coolers job is every bit as much to bring trans fluid temps up to operating temp as it is to cool them...to operating temp. Because of this, using the engine coolant (195-220F) to cool the potentially hotter trans fluid (225-325F looks to be when it would be running hot) back down works to an extent, but it's no where near as effective as a separate air/oil cooler like the NA trucks all got. The rad is metal core, the entire core will heat soak to the coolant temp including the trans cooler portion to an extent.

 

[mudgudgeon]

Quick question:
If you have an automatic tranny specific radiator that has transmission cooling section on the bottom, and lets say that you are not using that section for whatever reason (5spd conversion, separate tranny cooler, etc), would it be possible to use that section as a radiator for water-to-air intercooler setup? Seems like an ideal solution to me - no plumbing of air hoses, no fabricating, factory look, powerful fan blowing on it all the time, etc.

For a water/air intercooler to work, you want the greatest temperature differential possible between intake charge air, and the cooling water.
If you have intake charge air at 70c and coolant at close to engine operating temp of 82c, you'll be hearing charge air.
Even with coolant at ambient air temp, inefficiencies in heat transfer from charge air, through a core to water, than back out through a radiator to the air means you probably won't achieve intake air temps down to ambient air temps.

It would not be worth the effort of hooking it up and is likely to have a negative impact of any at all

 

[gerg]

I totally agree. That being said....if anyone does it I fully expect a build thread!

 

[J2P]

I just finished my front mounted intercooler after upgrading to a Gturbo. Following their lead, I bought a large ebay intercooler with 2.5" inlet/outlet. Piping was also bought on ebay as a general kit with t-clamps and silicone connectors. The intake adaptor was from Australian ebay and the airbox is a stock Duramax box with 6" fender feed and a 4" elbow that reduces to a 2.5" turbo inlet. It is holding 25 psi with no issues but I'm still testing. I followed the same plumbing as the new Safari coolers, through the rad support. It makes the path short and simple. Now I am going to remove the factory tranny cooler and installing a Derale 15960 under the cab inside the frame. Jason at Cruisin Offroad is building a mount so we can angle it up and out of harms way.

 

[CruisingSned]

J2P
Install looks good.
Which intercooler pipe kit did you use?
Thanks

 

[J2P]

Just a generic from Amazon I believe. Make sure if you order two that you get the same kit. I ordered a 2.5” first and then feeling I was going to be short I ordered a second which ended up being a 2.25’” kit somehow. I used 2.5” pipe from turbo to intercooler and 2.25” to the intake. The intake adapter is cast and sourced from Australian eBay.