Water to air intercooler

[shanfab]

Radiator is the 12x12x2" type , I still have A/C so it was a very tight to get it in . I still had to cut the grill to fit the Thermo in .
I do have a couple of pict's of the manifold in progress . but there on my other PC at home . it was a pretty easy job .
I just cut the back section out of the original manifold and added to it . I spent longer thinking about it than what it actually took to do it .

[Abitibi]

Sounds good.

I have another style of radiator for mine. It's a 3cm tube with 6cm circular fins (disks) all around and it's about 40cm long. I might need two of them but they should be way easier to mount and hopefully be more efficient. Has anyone used this type before?

Pictures will be welcome when you have a chance!

Cheers,
Mr. D

[THOMO89]

so yous reckon its worth it

[shanfab]

well I'm about $650 -$700 out of pocket for everything ( inc the bosch pump , but I made the manifold and all the other crap my self ) . I'd say it's worth it .

[THOMO89]

did you notice to power differance

[shanfab]

it's a bit hard to tell as I installed a new turbo at the same time . t

[THOMO89]

what size cooler do ya have

[shanfab]

over all size inc tanks is 12"x12"x4.5 . core size from memory is 12x9.5x4.5"
3" inlet and outlets .

[THOMO89]

oh right o the one im looking at is the 14 x 4.5 x 5

[84mksd33t]

Almost finished my SD33T frozenboost install.

[Red Dog 4x4]

This is my setup frozen boost core and other parts from them as well, intake plenem and filler tank built by ALL ALLOY CREATIONS, And custom made rad by PWR.

The injector pump is a one off custom unit flowing 125cc of fuel, up from the 85cc the standerd pump flows, it runs 15psi of boost at NO 6 inlet on the manafold.

[patrol_uterus]

Nice set up! What sort of kw's are you putting out?

[Red Dog 4x4]

Last power run was 224kw @ the rears, with 33'' on. I am geting more K's out of a tank up to 1000km out of 135lt tank usable about 120lt.

Towing is were you feal the power, it will sit on 100km/hour towing a 1tone camper behind will easally pull it all day.

[patrol_uterus]

I really like your set up, good workmanship its very neat and 224kw's is pretty bloody good! I''m running about 180kw's at the moment but would like to get some more out of it, i think I might be up for a rebuild soon any way. What mods have you got done to yours? Any internal work

[Red Dog 4x4]

Stock internales, 373000 km on the clock new motor was put in before i bought the truck 6 years ago, so probably got about 120 000 on it so far, stock DTS turbo system as i said the pump is the big helper in this system next on the list is change the injector lines and rebuild the injectors and a bigger turbo and intercooler, down the track though....

Would love to rebuild with HPC coated pistons new linings, and all the fruit to go with it...

[THOMO89]

is there anyone who makes an off the shelf intake manifold like yours or similar

[84mksd33t]

224rwkw - Damn!

That must be a fukton of fuel you are running! What are your EGT's like? Does it smoke lots? Are you running an aneroid?
224rwkw from a stock DTS turbo kit - I thought those turbos were only good for 140rwkw or so...or is it a custom job?

Do you have any problems blowing intercooler hoses running those worm gear hose clamps?

[awill4x4]

224rwkw on 16psi boost not in this or any other lifetime.
There are some some seriously modified TD42 comp trucks out there and it takes a looooooot more boost pressure than that to get to around the 200Kw mark without trying to get more power out of them.
Regards Andrew.

[Z()LTAN]

I was going to say something but you got in first andrew.

Ash runs almost 30 psi and has spent over $25k on his motor and only just sees 200rwkw

[Red Dog 4x4]

I do apologize....224 hp went and had a look at the print out.....My bad...


The turbo has a ball Bering core and has been high flowed, Thats how it came when i got the kit had to pay extra but it was worth is


The manifold i designed it and had it made to date i don't know of any one selling them, EGT are around 500deg C, and i don't think it blows much smoke, never followed my truck to know. The pump is the same as CBT racing so i'm not sure about all the detales but it has a boost compensator

[STALKER]

So the guys who are running boost pressure inexcess of 20Lbs is there any need to do any work to the head, piston or compression ratios? Or can I simply wind up the boost within reason?

[KiwiBacon]

This is my setup frozen boost core and other parts from them as well, intake plenem and filler tank built by ALL ALLOY CREATIONS, And custom made rad by PWR.

The injector pump is a one off custom unit flowing 125cc of fuel, up from the 85cc the standerd pump flows, it runs 15psi of boost at NO 6 inlet on the manafold.

These numbers just don't add up.

120cc/1000 shots on a TD42 needs 60psi boost to maintain an 18:1 a/f ratio (burning clean and safe). It's safe to say you're not injecting that much fuel.

15psi boost (at the manifold) and excellent intercooling on a TD42 can only burn 80cc/1000 shots at 18:1. This is 165kw at the crank at 4000rpm. You can gain a few more kw by swapping clean and safe for dirty smokey tune, but from there all extra fuel injected goes out the exhaust without adding power.

165kw is roughly 222hp. The 222hp you have on your dyno sheet is predicted crank hp, not power to the ground.
Stock fuelling is around 50-65cc/1000 shots with 12psi boost.

[UGOTNUFN]

This is my setup frozen boost core and other parts from them as well, intake plenem and filler tank built by ALL ALLOY CREATIONS, And custom made rad by PWR.

The injector pump is a one off custom unit flowing 125cc of fuel, up from the 85cc the standerd pump flows, it runs 15psi of boost at NO 6 inlet on the manafold.

These numbers just don't add up.

120cc/1000 shots on a TD42 needs 60psi boost to maintain an 18:1 a/f ratio (burning clean and safe). It's safe to say you're not injecting that much fuel.

15psi boost (at the manifold) and excellent intercooling on a TD42 can only burn 80cc/1000 shots at 18:1. This is 165kw at the crank at 4000rpm. You can gain a few more kw by swapping clean and safe for dirty smokey tune, but from there all extra fuel injected goes out the exhaust without adding power.

165kw is roughly 222hp. The 222hp you have on your dyno sheet is predicted crank hp, not power to the ground.
Stock fuelling is around 50-65cc/1000 shots with 12psi boost.

There is some serious issues if you need 60PSi to burn 120CC of fuel. 120CC of fuel in a well intercooled/turboed TD42 will yield 150RwKw all day on 35" tyres at 23-27 Psi with good safe AFR's. Which equates to around 200RwHp, its a very common upgrade fuel figure which always yields the 150RwKw figure with <30 Psi of boost.

But having said that 16Psi is not enough to burn 120CC safely nor make 224RwHp

MAtt

[KiwiBacon]

There is some serious issues if you need 60PSi to burn 120CC of fuel. 120CC of fuel in a well intercooled/turboed TD42 will yield 150RwKw all day on 35" tyres at 23-27 Psi with good safe AFR's. Which equates to around 200RwHp, its a very common upgrade fuel figure which always yields the 150RwKw figure with <30 Psi of boost.

Yeah bugger,had a typo. That was 170cc at 60psi.

120cc will provide well over 200kw at the crank, 3,500rpm, A/F 18:1 and 34psi boost with a very good intercooler. You can lower boost a little and still be okay, but under 30psi it's going to be very smokey and a large chunk of that 120cc will go out the back unburnt.

[UGOTNUFN]

There is some serious issues if you need 60PSi to burn 120CC of fuel. 120CC of fuel in a well intercooled/turboed TD42 will yield 150RwKw all day on 35" tyres at 23-27 Psi with good safe AFR's. Which equates to around 200RwHp, its a very common upgrade fuel figure which always yields the 150RwKw figure with <30 Psi of boost.

Yeah bugger,had a typo. That was 170cc at 60psi.

120cc will provide well over 200kw at the crank, 3,500rpm, A/F 18:1 and 34psi boost with a very good intercooler. You can lower boost a little and still be okay, but under 30psi it's going to be very smokey and a large chunk of that 120cc will go out the back unburnt.

Geez you scared me there for a while, i was sitting back thinking "thats not a normal post from that man".

Glad we are on the same page.

[sswaffie]

There is some serious issues if you need 60PSi to burn 120CC of fuel. 120CC of fuel in a well intercooled/turboed TD42 will yield 150RwKw all day on 35" tyres at 23-27 Psi with good safe AFR's. Which equates to around 200RwHp, its a very common upgrade fuel figure which always yields the 150RwKw figure with <30 Psi of boost.

Yeah bugger,had a typo. That was 170cc at 60psi.

120cc will provide well over 200kw at the crank, 3,500rpm, A/F 18:1 and 34psi boost with a very good intercooler. You can lower boost a little and still be okay, but under 30psi it's going to be very smokey and a large chunk of that 120cc will go out the back unburnt.

Is this BSFC (120cc's) Dougal ?

the majority of everyone's fueling figures will be from test injectors
12sd12's which doesnt relate to BSFC (to a degree)

120cc's on 12sd12's equates to usally around 220 RWHP
20 -22psi of boost for safe levels with a good intercooler

16psi and that intercooler will only be good for short burst
Sustained load it will melt to pieces

Regards
Swaff

[KiwiBacon]

There is some serious issues if you need 60PSi to burn 120CC of fuel. 120CC of fuel in a well intercooled/turboed TD42 will yield 150RwKw all day on 35" tyres at 23-27 Psi with good safe AFR's. Which equates to around 200RwHp, its a very common upgrade fuel figure which always yields the 150RwKw figure with <30 Psi of boost.

Yeah bugger,had a typo. That was 170cc at 60psi.

120cc will provide well over 200kw at the crank, 3,500rpm, A/F 18:1 and 34psi boost with a very good intercooler. You can lower boost a little and still be okay, but under 30psi it's going to be very smokey and a large chunk of that 120cc will go out the back unburnt.

Is this BSFC (120cc's) Dougal ?

the majority of everyone's fueling figures will be from test injectors
12sd12's which doesnt relate to BSFC (to a degree)

120cc's on 12sd12's equates to usally around 220 RWHP
20 -22psi of boost for safe levels with a good intercooler

16psi and that intercooler will only be good for short burst
Sustained load it will melt to pieces

Regards
Swaff

I was using BSFC of 260 g/kwh at full torque and 300 g/kwh at full power. These are the best figures I have, I'm happy to modify them if someone has better data.

BSFC doesn't change the amount of air you need to burn a set amount of fuel, it just changes how much power you get from burning that fuel. If you can improve the engines efficiency (lowers BSFC) then you still need the same air to burn the same fuel, but you get more power and torque from it.
The air/fuel ratio is the only part that changes how much air you need, go too low and you get smoke with high EGT's. The 18:1 I used is clean and safe, between 18:1 and 16:1 it starts to smoke, at 16:1 it'll smoke no matter how good your injection system is.

[sswaffie]

What I am getting at is when people quote there pump was set to 120cc's of
fuel delivery it would most probaly be set on 12sd12 150 bar test injectors and
not actual fuel flow at the nozzle which is used in the vehicle

For example 1hdft uses 87cc's of fueling at 1800 pump rpm to produce 125 crankshaft Kw
Wich is alot of fuel for 10 odd pounds of boost

But they test these pumps with also 12sd12's 150 bar
And it doesn't really mean that's what they are flowing at the nozzle of the vehicle

Food for though to work into your appreciated equations

Regards
Swaff

[marty]

Are you saying test injectors flow more than the actual injectors used?
If so would you happen to know by how much?

Marty

[sswaffie]

It all depends on the injector used from oem , the Nissan td42 single hole nozzle will flow totally different
Then that of a Toyota 1hdft etc ,also nozzle opening pressures Are totally different aswell