Outer Limits 4x4 Board

Just finished this, it bolts up to the 1hz and 1hd-t I'll sort out the exchanger, pump, pressure relief resivoir next and should have complete kits or just the coolers for sale soon, once I have done some more testing.

Very nice mate!

Are you able to make them a little wider? When i did the calcs for my intercooler it needed a much larger core than that. But i am running 25psi.

Top work!

Thanks mate.

Yeah I can do a bigger one for you guys running 20psi and up

Might do inlet and exhaust manifolds too if there are a few of you guys chasing more power.

Thought about using 2 cores?

This is my attempt, not as flash as your ones but not bad for built in the backyard lol

Looks good, is topping up the oil hard? The test I have done for the core I have used showed great results. These little cores will actually flow and keep cool about 500hp worth of air flow. And no lag

But yeah will definitely do a bigger one for high boost set ups like yours.

How much power are you making out of that thing? Sweet looking truck mate.

Yeah getting to the oil is a little tough but doable. Biggest issue is how massive it is, it sits about 75mm out of the bonnet lol.

I havnt dynoed it since the cooler was added and boost was increased but id say it would be around the 150-170kw mark with 500+ nm
Ill have to get it on the dyno b4 my next racing event.

Glad u like the truck mate!
Here is a vid of it getting to about 100kmph
http://www.youtube.com/watch?v=2jQ97yEEZUA" onclick="window.open(this.href);return false;
Here is a vid of the lack of lag 2nd gear
http://www.youtube.com/watch?v=j3-Y77te ... re=related" onclick="window.open(this.href);return false;

id be interested in one of these mate. what will your kit be worth?

Ill know a price in the next few days, got pumps coming from USA, just trying to fit the heat exchanger, the 75 series are pretty tight with all the air con gear up front.

My plan it to sell complete kits for around $1300

Very interested. What is your definition of a "complete kit". Keep us posted. Keep up the good work. Ed.

Complete kit will be
intercooler
heat exchanger
pressure relief reservoir
pump
hoses
clamps
mounting brackets

Everything you should need to intercool your truck.
Thanks for the positive feed back.

will there be a thermo fan for the heat exchanger

On the 75 series room is very tight so a fan may have to go on the front of the exchanger with some grill mods. On the 80 series is no probs.

We are still waiting on the pumps to show up from USA.

Are you going to post pre and post intercooler dyno figures for this intercooler? Say standard 80 series 1HDT and then intercooled with fuel turned up? And temps...

Yeah sure will, still need a 1hdt guinea pig if anyone is keen? You will get free installation.
At the moment we are working with a 1hz with a turbo.

Turboshop wrote:On the 75 series room is very tight so a fan may have to go on the front of the exchanger with some grill mods. On the 80 series is no probs.

We are still waiting on the pumps to show up from USA.

I want to get the heat right out of the engine bay of my hzj75 troopy, so I will be remote mounting the heat exchanger. I think I will be able to get it up behind the fuel tank. For that reason I would want a fan on it. I would also like both water fittings on the back of the cooler. Would you be prepared to tailor a kit to suit me? I've already fitted a supplementry electric fan to the radiator and it sure is tight in there. Denco supply spacers and move the radiator and condenser back to create space for the exchanger in their intercooler kit. Ed.

Im looking at building a custom exhaust manifold but would be interested in one of yours if your still contemplating building them.

I got my water to air from the states approx 1/3 the cost of what was available in Aust including shipping. I have a few mates at work who are interested in mine, I will point them in your direction.

I also just got Water Meth injection looking forward to installing very soon.

Yeah Ed i can do it to suit your needs, I think there will be a few guys wanting to rear mount. The exchanger with fan on the side of the bar work tray is becoming a bit of a trend....

Turbo 80, yeah I'm keen to do you a manifold, if you have a look in the welding thread in general tech, you will see a pic of one of my manifolds under construction. The stock cruiser manifold is very poor flowing, so i anticipate fairly impressive gains from the exhaust manifolds. I did some back to back dyno testing on my manifolds on a 1.8L ca18det petrol motor and achieved 58rwhp gain from the manifold alone.

Not sure why these pumps are taking so long, sorry for the delay guys.

Cheers,
Luke.

Turboshop wrote:Looks good, is topping up the oil hard? The test I have done for the core I have used showed great results. These little cores will actually flow and keep cool about 500hp worth of air flow. And no lag

But yeah will definitely do a bigger one for high boost set ups like yours.

How much power are you making out of that thing? Sweet looking truck mate.

Looks good Luke. I'm in the middle of sorting something in between yours and Zoltans with a larger core about the size of Zoltans 2. Not pulling you down but my concern too was the size of the core as I was originally modding a Suburu unit but didn't like how it fitted. When quoting stuff like supporting 500hp is thsi still more petrol related where they are not boosting all the time. I'd love to know how a 500 hp ocassional boost scenario compares to a diesel situation where they are boosting almost 100% of the time. This was why I decided to go a little bigger. Mind you it's in an 80 so a bit more room but still fiddly as the 1HD-FTE (transplant) rocker cover layout is a bit of a pain.

Looks good Luke. I'm in the middle of sorting something in between yours and Zoltans with a larger core about the size of Zoltans 2. Not pulling you down but my concern too was the size of the core as I was originally modding a Suburu unit but didn't like how it fitted. When quoting stuff like supporting 500hp is thsi still more petrol related where they are not boosting all the time. I'd love to know how a 500 hp ocassional boost scenario compares to a diesel situation where they are boosting almost 100% of the time. This was why I decided to go a little bigger. Mind you it's in an 80 so a bit more room but still fiddly as the 1HD-FTE (transplant) rocker cover layout is a bit of a pain.[/quote]

A 4 liter motor at 4500rpm is inducting 9000 liters per minute of air at lets say 15psi and 90degreese Celsius, if that air can be dropped to say 30 degrees in the split second it takes the air to travel the length of the intercooler, which it can. ( length of intercoolers is far more critical than width)
then it does not matter how long you pump the air through, the formula is the same. the variable which can however affect intake temps on prolonged boosting is rising water temp. So the water flow rate, volume and time exposed to ambient air flow must be fine tuned to suit the diesel engine. I am very confident in the cooler and i am working on getting the water variables spot on, i,e; exchanger, fan, pump and water volume. Hope that all makes sense. I am a big fan of testing and will keep you guys up to date with figures as i fine tune this set up.
I hope i am able to answer any concerns you may have.

So obviously the bigger the radiator/exchanger the more scope to get the cooling right. I got the Suburu radiator with the bits I got but it looked far too small to be fully effective and would be about half the size of the available space and the rad I intend to put in. I'm hoping to find a simple controller that will allow playing and fine tunign of the Suburu pump too seeing as it lends itself to variable speed pumping without issue given it runs that way from factory.

Turboshop wrote:Yeah sure will, still need a 1hdt guinea pig if anyone is keen? You will get free installation.
At the moment we are working with a 1hz with a turbo.

Id love to be your 1hdt guinea pig. But have absolutely no funds :(

fester2au wrote:So obviously the bigger the radiator/exchanger the more scope to get the cooling right. I got the Suburu radiator with the bits I got but it looked far too small to be fully effective and would be about half the size of the available space and the rad I intend to put in. I'm hoping to find a simple controller that will allow playing and fine tunign of the Suburu pump too seeing as it lends itself to variable speed pumping without issue given it runs that way from factory.

The subaru coolers on a RS liberty can support about 200kw at the flywheel in a 2L 4cyl. They tend to run out of flow before cooling becomes an issue. The intake neck is the main bottle neck. Im sure you noticed the design was not that great. Quite a few guys have run larger intercooler radiators (bout twice the size) and have had good success with keeping the intercooler coolant temps down. Problem with a water to air is that water takes longer to heat up than air, but on the other side of the coin it takes longer for the water to shed the heat. The subaru dual speed setup for the pump ran slow speed till the ecu sensed that the throttle was over ~80% for greater than 3 seconds, then it kicked in the high speed. It just ran a simple resistor and two solenoids to activate the dual speeds. I ran the water to air on my subaru for a while, but in the end i swapped to a larg air to air unit.


Layto....

Yeah Layto I started cutting up the Suburu unit to change things around a bit to suit me and fix a couple of issues but in the end decided it was still going to look a bit amatuerish and wouldn't sit as good as I wanted so I've plumbed otu for a proper water/air core of a better size to make tanks as I need.

I tossed up over water/air air/air for ages but in the end the air/air plumbing for my 80 was going to be much more of a headache than I wanted so I'm stayign water/air. I don't like the plumbing running around the chassis rials as most do with at least one pipe and mine looks to be a little worse as it has the ute based FTE in it rather than the wagon version which has a slightly different orientation for the turbo in/out to suit intercooler better. The central rocker cover hump also upsets things a bit too. Rather than root around with this I'm sticking with water/air and as others have done I'm going as big an exchanger as possible. Also my water/air core is probably nearly twice the size of most that are used.

I wonder how the Denco type ones actually go with the fairly small core coupled with a pretty small exchanger as the one I saw didn't even take up a full half of the condensor area and from memory I don't recall if it had a fan.

i would have liked to do a neat air to air but I really have not seen one plumbed yet in a layout I'd be totally happy with.

Just a quick update,
The pumps arrived and we set the system up. Mounting location for the exchanger on the 75 series is still something i am working on. for the moment we just have an old exchanger mounted in front of the grill and behind the bull bar.
We have driven it around all week to monitor egt's and make sure we have no leeks. It is working great egt's have dropped way down. This weekend we will give it some more boost and fuel.

Hopefully we can get it on the dyno very soon, unfortunately our test mule is now sporting a very bent rear diff housing. So that may delay us a bit.

Any progress? This thread is interesting.

We have wound the boost up to 15psi for more testing and it is going great. EGT's are still in the low 400's
I just need to get it on the dyno to confirm % power gain, but the 'ol seat of the pants' tells us this cooler has made a huge difference!
More hours in the day would be great, a constant flow of customer cars, trying to finish the LS1 Jeep comp truck and stretching my Bundy and 4 linking it is keeping me very busy.
But i will be doing a run of 10 of these inter cooler kits very soon due to the interest and positive results that have come through so please keep your inquiries coming in.

Regards;

Luke.

hey mate im very keen on one of these kits, when will you be selling, how much $$ and where are you based ?
cheers chachi

Hi Mate, I have an HZJ79, was running a PWR barrel type but want to try yours, all I would need is the intercooler, I have everything else. Of course I would like it as big as I can get because I already have the PWR size and want bigger for more cooling.

When you get a price for just the intercooler please let me know, and if you are making a bigger one can you posta pic?

Thanks!

Louis

Hi guys, sorry to the late reply to those of you who have contacted me. I have been totally swamped with work at the moment. I am hoping to spend some time over the xmas break getting these intercoolers happening.
The set up is working great under all conditions we have been able to throw at it, now its just a matter of fine tuning the mounting of the heat exchanger, so that these kits can be easily installed.

i am still on the hunt for someone with a turbo diesel 8o series wanting one of these setups, so that i can make this kit compatible with both models.

Regards;

Luke.

I will lend you my factory turbo diesel 80 series if you want. Im just up the road aswell.