Outer Limits 4x4 Board

marin wrote:install my GU airbox and get andrew to do that 1 weld needed to get the air from my GU airbox to my turbo.

You going to use the standard GU aircleaner that goes behind the LH headlight?

GQ TROL wrote:

marin wrote:install my GU airbox and get andrew to do that 1 weld needed to get the air from my GU airbox to my turbo.

You going to use the standard GU aircleaner that goes behind the LH headlight?

Yeah, that's the 1, picked up a 4.2T airbox, although i've now heard that that the 3L airbox has slightly better flow.

marin

Depending on the rest of your setup (turbo etc), you might find the Nissan paper filter element a bit restrictive. But in terms of bolting in something that fits easy, its great.

marin wrote:

matt.mcinnes wrote:
Your intercooler is waiting for your services time for some drilling and tapping. You will need an M5 tap and suitable drill bit

SNIP

GRRRRRRRRRRRRR Bloody typical.... I fly out to WA for 2 weeks on monday.

Well rather than wait for Marin I have re fitted the cores, all I need to do now is drill and tap the holes for the end caps. Then back to Andrew for final fabrication.

matt.mcinnes wrote:

marin wrote:

matt.mcinnes wrote:
Your intercooler is waiting for your services time for some drilling and tapping. You will need an M5 tap and suitable drill bit

SNIP

GRRRRRRRRRRRRR Bloody typical.... I fly out to WA for 2 weeks on monday.

Well rather than wait for Marin I have re fitted the cores, all I need to do now is drill and tap the holes for the end caps. Then back to Andrew for final fabrication.





SNIP

Well, i'm back, do those holes still need taping? But i'm out again on monday lunchtime..... so i need to work fast! (unlike at work LOL)

marin

What time is it Marin

matt.mcinnes wrote:What time is it Marin

Time for you to be WORKING!

Well anyways, got all the holes done for the end caps (and got to bed about 3:15am and still passed my fork licence 2day ), so we can now proceed.

Also picked up a bag of 100 o-rings for you 2day........

marin

Well Marin managed to drill all is holes right

PS Tks for the O rings and be sure to keep the receipt I need the part No

top job will you be selling thes intercoolers if so would it fit 12ht land cruiser thanks

12ht wrote:top job will you be selling thes intercoolers if so would it fit 12ht land cruiser thanks

Yes and Yes, what started as a home brew intercooler has grown a little, we have 3 basic designs we are working on if you read back through the thread. Which ever of the 3 suits the 12ht best can then be tailored to suit the the feed from the Turbo to the inlet keeping pipe work to a minimum and therefor lag.

PM sent.

Well Marin heads for Perth again on Monday and his Mav is heading here

Awill4x4 has the intercooler for final welding and fabrication and while this is been done I will get the Mav on Dzltec's dyno for some pre intercooler test figures.

This way we have an set of indipendent figures to compare too, from before and after.

Once the manifold/intercooler is complete it will also be flow tested so we can compare it to one of our generic 4 core intercoolers.

matt.mcinnes wrote:

does it come with the orange cushion? or is that an extra?

I'm sure you can afford a cushion

Spent the arvo at Dzltec's,

Marin's Mav is booked in for the dyno Wednesday for it's first round of tests to give us a base line.

Awill4x4 has some fabrication to do as we are now doing the skin for the second 8 core. Along with the fabrication of the manifold for Dzltec's TD42, this is going to be different to Marin's but still an improvment on the stock single entry set up.

So watch this space for an 8 core twin turbo TD42 as well

matt.mcinnes wrote:Spent the arvo at Dzltec's,

Marin's Mav is booked in for the dyno Wednesday for it's first round of tests to give us a base line.

SNIP

Does the dyno read that low?

marin

marin wrote:

matt.mcinnes wrote:Spent the arvo at Dzltec's,

Marin's Mav is booked in for the dyno Wednesday for it's first round of tests to give us a base line.

SNIP

Does the dyno read that low?

marin

yes

Well the numbers are in Marin's TD42 with it's DTS Turbo kit makes 83rwkw at 12psi, intake temps are approx 90C.

Andy @ Dzltec has all the number on file.

I have never had the chance to test the intercooler on my 40 with the pre and post temp sensors hooked up with the snorkel fitted. Only one quick run prior to Vic Winch with just the intake temp.

1st graph is
Orange - Throttle Positon
Green - RPM
2nd graph
Dark Blue - Load
Light Blue - Boost PSI
3rd graph
Red - Pre intercooler Temp (Rescaled by 1.82)
Spring Green - Post intercooler Temp (scale 1:1)

The Wolf V500 does not support 2 air temp sensors so the external map sensor input has been re graphed to use an air temp sensor, but at a scale of 1:1.82. In other words the red line is almost half scale, and the reason the graph shows it under the post intercooer temp.

After warming up the engine for over 20min pre intercooler temps were 45C post intercooler 26C ambient 19C

The run shown in the picture is 30sec up hill starting in 2nd gear.
Pre intercooler temp maxing at just over 80C post intercooler 31C ambient 19C



You can see even though the 2 scales are different in the bottom graph, my intercooler basically flat lines my intake temps even at full boost.

All I can say is Awill4x4 is a GENIUS

When I picked Marin's Mav up at DzlTec I also picked this up. It was a little dirtier but shot blasted it was ready for the surgeons red pen

This one will be a simpler version of Marin's as this intercooler makes life much simpler.

DzltTec's however is an 8 core single pass due to his twin turbos' making around 180C pre intercooler

Marin left a GU TD42T air box for me to fit while he is away at one of Rio Tinto's, this will replace the DTS set up.

The current feed from the turbo is in my opinion very poor at present the DTS set up pretty much doubles back on it's self, the sharp angle is not the best.



The GU TD42T air box bolted stright in holes in the GQ inner wing easy as and will sit where the GQ pre filter used to be.

Picked the intercooler up from Awill4x4 today to re fit the cores and seal it all up for flow testing and then pressure testing prior to fitting.

While at the same time dropping a set of end plates and tubes in for Awill4x4 to start the next project a stright 6 3.5Ltr BMW 3 series

Oh and anyone out there with a GU TD42 to play with pm me.

matt.mcinnes wrote: DzltTec's however is an 8 core single pass due to his twin turbos' making around 180C pre intercooler

So he's running around 35psi?

KiwiBacon wrote:

matt.mcinnes wrote: DzltTec's however is an 8 core single pass due to his twin turbos' making around 180C pre intercooler

So he's running around 35psi?

I'm sure Andy at DzlTec can answer that better.

Kiwi, it can go as high as 55psi.

The advantage of compound turbocharging.




Andy

Dzltec wrote: 55psi.

Andy

Ok cores fitted and the end caps sealed and all ready for testing at Hi Port on their vacuum flow bench. Monday

Hi Port specialize in porting and polishing and other performance enhancements and were good enough to flow my intercooler.

MM, Exactly what does the info from Hi Port tell you. As in what do they do and how do you apply this info to your settup...

RED60 wrote:MM, Exactly what does the info from Hi Port tell you. As in what do they do and how do you apply this info to your settup...

It will show how well the air flows through the intercooler and how restrictive the intercooler is.

My intercooler results were.
http://forum.ih8mud.com/2771302-post32.html

That thang is sex on 6 legs!!

Oh and just read the laymans interpretation of flow testing results from link - SWEET!!!