TD42 Intercooler sizes

[JDGQ]

Hi guys,
i've had a quick search for average cooler sizes but all i can find is water to air specs.
I managed to pick up an air to air intercooler for the right price a couple of years ago but never fitted it up due to laziness.
All i'm running is a standard internals pump with an aneroid top hat and switzer turbo pushing out no more than 15psi.
The cooler measures in at 600x300x75mm.
I don't plan on doing any turbo or pump mods down the track, just looking to fit the cooler to help keep EGT's in check and keep a bit more longevity in the motor.
Is the intercooler i've got going to be way too big for my desired results?
If so what size would be more appropriate?
Don't want to go top mount, happy to run front mount.
Even keen to swap mine for a smaller one but this isn't the right area to be "advertising" such things (nice mods, nice mods..)

Suggestions?!

[MikeH]

Its not too big to cause problems, just install it.
better than too small.

[JDGQ]

Really? cause i thought there's a point where they can be too big and end up just slowing the air flow down? i mean the factory ones are only quite small.
Then again i'd be pissed if i fitted one that was too small and have to fit up a bigger one down the track...
What size do you have fitted Mike?

[GaryP]

Fit the one you have it's the perfect size for your application

[MikeH]

I was using a 600x300x76mm bar and plate front mount, but it was struggling. Only 1-2 psi pressure drop but I think it was heat soaking. It was running about 180kw and the engine died a heat death (or a cracked block we don't know which came first, the NA blocks aren't as strong as the turbo blocks) being driven at 4400 rpm and still accelerating in 5th gear, we were approaching 200kph wheel speed. You'd never keep the boot into it for that long on the street so that cooler will be satisfactory for just about any street application. It had 3 inch piping and a largish plenum on it. It was running beautifully until the red mist took over.
An incorrectly matched pump and turbo contributes more to lag than any sane intake tract volume. The lag of that system was effectively nonexistent, with load on it it would build boost just about as quick as the engine built revs. It made 10psi just revving it in neutral.

that size is a struggle to fit in the front of a GQ, you will need to make a new bonnet latch support and cut a bit of the back of the grille out. I didnt have a/c and I still had to trim the grille a bit.

[JDGQ]

Cool thanks for the insight mike.
Yeah don't have anywhere near that much power, last dyno run saw it pull 125rwhp.
I'm still running ac and am comfortable with cutting the grill up to make it fit. Still has a standard inlet manifold and dual batteries so it's pretty tight under the bonnet. So pipings probably gonna be no bigger then the inlet tract (which is not much bigger than 2inch methinks).
Any suggestions where to get bends and pipe from?

[Clanky]

I have exactly the same setup except for a Mitsu turbo.
The front mount fits fine with the mods mentioned above (I have AC too), and I even managed to rubber mount mine, as it a touring truck and can suffer corrugations etc for long periods.
I run 2" SS piping to / from the cooler and havent found it to be insufficent. Makes it much easier to pipe up with all the other crap under the bonnet.
However, I always wondered if there is an advantage to go up a size to 2.5 inch, given that I wont be turning up the boost above 15psi at the manifold and that space is at a premium.

Can supply you some pics if you PM me with your email.

[JDGQ]

Thanks clanky,
PM sent.
Yeah I'll definatly be looking to rubber mount it and remake the radiator support panel bracket.
Sounds like I'm gonna be starting the next project very soon then!
Thanks for the advice guys, I'll try posting some pics for future reference.

[MikeH]

hole in the manifold is 60mm, so you might want to do the cool side in 2.5 inch.

[JDGQ]

hole in the manifold is 60mm, so you might want to do the cool side in 2.5 inch.

Yeah i always wondered why i'd heard of people running 2.5 inch pipe on the cool side. The turbo's only running a 2.5 inch inlet from the airbox and the snorkel is just your average plastic snorkel so i don't see much point in running 3 inch cooler pipes as it's restricted at one point or another.

Still trying to find a suitable place to get some pipe from brisbane northside.

[MikeH]

Universal piping kit off ebay is what I used.
something like this,
http://www.ebay.com.au/itm/INTERCOOLER- ... 1c14776e5d" onclick="window.open(this.href);return false;
you might have to go with 2.5 inch due to availability.

to shorten the pre-bent tubes to what you need:
use the sections of straight hose, slip it over to use as a guide to mark the tube, then use it to grip the tube in the vice.
cut the end off.


to re-dimple use a block of soft pine and a really big screwdriver and a hammer as shown:




and how mine ended up.. I would put yours the other way up because the a/c piping will interfere.

[JDGQ]

Cool thanks for the link Mike, that looks like it comes with everything i need and its all pretty like too!

looks like the job will be a hell of a lot easier with the bullbar off too so might have to rip that off!