Outer Limits 4x4 Board

ok well time that i got on with the intercooler but all that was achieved was working out where to mount it. first of i was going to mount it north south but then i was going to have bonnet clearance issues. so in the end it is going to be easier to mount it east west and then i wont have any bonnet clearance issues.

intake flange adaptor



l/h view



r/h view



proposed finished look

VERY NICE...
WHAT TURBO HAVE YOU GOT ON IT??
HOW MUCH DID YOU PAY FOR IT??
I LOOKING TO PUT ONE ON MINE

sweeet!

ill be interested to see how it fares against my setup!

yeah but you have an advantage with that hole you have to put in your bonnet giving you some more cool air.

ok here are some pics of the heat exchanger that i have done for the cooler. i am ging to have to change the port on the top right as my grill does not fit. it is fitted with 2 10 inch therms that have dimples on the blades like a golf ball. apperntly these will flow more than a spal thermo.
currently driving around like you see in the pics without the thermos running and water temps are still good.

I am very interested to see how this goes. I have herd a lot about the laminover intercoolers, and will prob get a setup for my td 80, a littl down the track

Can you just confirm for me that the inlet (from the turbo) is on the top of the intercooler body? There is plenty of space between the bonnet and the proposed inlet?

Very interested in how you go with this.

Cheers.

hey mate as you can see from my first pic with the wonderful drawing that i did, the supply from the turbo will be ontop of the cooler. but this will be very close to the bonnet i think this will be about 40mm high and will be extremely close to the the under bonnet mating.

Can you use basically the same setup as the generic GQ cooler where it comes out the bottom? I was looking at this way and the only thing i could see holding it back was the angle the inlet flange was on.

personally, I would be looking at cutting the top off the intake manifold plenum and mating the intercooler directly to the manifold,
(check out Z()ltans efforts) I would modify the rocker cover to accomodate it if needed so it fits under the bonnet.

It is a shame to spend so much on a shit-hot (shit-cool??) bit of gear and compromise it with poor inlet/outlet runners.

my2c (gst not included)

80's_delirious wrote:personally, I would be looking at cutting the top off the intake manifold plenum and mating the intercooler directly to the manifold,
(check out Z()ltans efforts) I would modify the rocker cover to accomodate it if needed so it fits under the bonnet.

It is a shame to spend so much on a shit-hot (shit-cool??) bit of gear and compromise it with poor inlet/outlet runners.

my2c (gst not included)

The in and out although not 100% ideal will actually work quite well due to the internal layout of the cores and shows the versatility of the generic unit. You can feed in and out many different ways.

ok initally i wanted to mount it north south but there is not alot of room under the bonnet it would of been very close to the oil filler. and the cooler would have t be mounted on an angle down to wards the radiator.
the other issue trying to mate it up to the intake manifold with it being on an angle and then trying to get the mounting bolts done up would be a pita.

ideally like matt has done with the gq and gu intergrated into the intake manifold would be the best option. but i wanted it so i could change it back to standard if something went wrong. mounted to the intake manifold would require repositioning the throttle. and then accessing the injectors would be a hassle if needed.

still in the planning stages might change my mind like a dozen times before it gets fitted. might have to price up an intake manifold for it to see if that is an option.

might try again on the weekend and see if intergrating it into the manifold is do able

what are the dimensions of the cooler? I'm really curious to see this thing fitted up.

Length, width, thickness?

cooler size is 430x192x72

okay so option 2 for mounting the cooler is to intergrate it into the manifold.

reasons this is better
- less heat soak from engine
- should be less restriction this way (airflow)

problems
- accelarator cable is in the road
- engine dipstick is in the road
- cooler cannot go over rocker cover (serviceability)






so if i do go with intergrating it into the manifold i would like to use the existing cross over pipe. cut the end of the pipe off put bolt on flange onto pipe and onto side of cooler so cross over pipe can be removed. the major hurdle with intergrating it into the manifold is the accelarator cable if any body has any ideas on what i can do to over come this problem let me know.

Have at look at how this is mounted. Might give you some idea's.

http://www.crosscountry4x4.com.au/produ ... ductid=115

you could look at relocating accelerator cable connection to rear of manifold and usng a longer link rod to the injector pump?

Dip stick would be fairly easy to modify the tube so it is re-bent to come up in a different location.

clearance to the rocker cover could be trickier, what is the air path like on the inlet manifold side? is it mirror reverse of what is visible in your 2nd last pic? if so, could you mount it so the outer edge is over the manifold and air exits downward into the penum?

ok what you see in the 2nd last pic is what the cooler looks like on the other side just a mirror like you were saying. i was thinking about putting it onto the manifold centred between the 2 middle ports on the end caps should give enough to weld it to the manifold below the end cap plates. if i was to go right to the outer edge i would have to check if it will cover the rocker cover. which i would prefer it didn't. if i mountit centred on the 2 centre holes of the end caps it stay well away from the rocker cover.

with the accelartor i would have to look at that for an option but how would that go as where it is currently mounted when you accelarte it moves from the l/h sideof the car to the r/h side of the car.

sounds good, if you mount it as you say, you could extend the plenum to the outer edge of the cooler?
I was thinking the accelerator cable bracket and the cam/linkage etc could be fitted at the rear of the inlet manifold (near no.6 inlet runner) basically exactly as it is now, only further to the back of the manifold.
the cable would probably have enough length to be able to loop to there.
Then you would need a longer rod to link the cam/linkage to the throttle arm on the pump.
the action of the accelerator would stay the same

ok now i see what you are getting at which is not a bad idea. probably by this time toomorrow i will have another idea about mounting it

Food for thought, just one I'm playing with a the moment, not the ideal placement but should still do what we need of it.

what are you looking at putting that on matt

ledgend80 wrote:what are you looking at putting that on matt

3Ltr Grenade (Nissan)

matt.mcinnes wrote:

ledgend80 wrote:what are you looking at putting that on matt

3Ltr Grenade (Nissan)

thats OK then, doesnt matter that it is the ugly duckling, it will be shrapnel before long anyway








ugly duckling in comparison to other awesome-ness from Matt

ok well i got 2 manifolds the other day and this is what i have done with one of them so far( sandblasted and cut out hole for cooler. and this is pretty how much it is going to look.

will it clear injector lines?

double post

Good to see the young 'un learning about 4x4's early.....

remember the intake sits on an angle to the head

The inj lines are quite close too, even with the amount of rise i gave my intercooler it was still hard to get to them.


But im sure you'll be finding all this out soon.

Ya see my modified accelerator cable and linkages i posted last night?

If ya need the info or better pics of it let us know mate.

Good luck.

ok the biggest draw back with how i am going to mount it, is there will be no access to the injector lines/injector without removing the intake manifold.

if you have a look at the very first pic in this post (top of page) you can see the injector lines as to where they sit in relation to the manifold. as long as i mount the cooler in the manifold no lower down then to the bottom of the angle on the manifold i should be right.

z()ltan just had a look a your cable setup looks pretty good. may have to borrow that idea off of you if i cant come up with anything else.what did the cable cost to get made up. (pm me if you want with the price)