Outer Limits 4x4 Board

Some of you here have seen my fabrication projects here before and here is some info and photo's of my latest project.
An interesting project I've been involved in lately is fabricating and welding a top mount intercooler system for an early 80's petrol Jackaroo. We considered front mount's but a severe lack of space meant we decided to go down the top mount route.
The car owner fabricated his own turbo system using a blow through setup on his existing carby, it worked quite well but detonation under high temps with standard fuel meant he needed to cool the intake charge. That's where I came in as I've built a number of custom intercoolers for different applications and this was quite a challenge.
He managed to source a factory diesel turbo bonnet/scoop/seal assembly so that gave us core sizes we needed. I would have preferred a slightly longer core but due to the carby position we were stuck with what we eventually ended up with. Luckily the height we had to play with allowed us to us a 75mm thick core so volume was quite good considering it's only a 2 litre engine.
He's had it on for little over a week and is very happy with his performance gains and the ability to now run the car on standard fuel. Throttle response is excellent and the cooler seems to work a treat with a very nice temperature drop on the outlet side.
I guess it just goes to show that not all top mounts should be disregarded for performance gains. (depending on application of course.)
Regards Andrew.

fark you do a grouse job !!!!!
looks the goods !!!
wat power gains did it achieve ???
(or not tested !!)

What price for a GQ Intercooler, I need 1 for my truck.

another nice one dude looks wicked!

Cheezy4x4 wrote:What price for a GQ Intercooler, I need 1 for my truck.

It needs more then just that

Nice work!!

How many hrs did it take?

Moose, we haven't done any before and after dyno tests. The main point was to prevent detonation and any power gain was a bonus. The owner says that in "seat of the pants" driving it feels much stronger throughout the rev range. Apparently a Jeep renegade soft top 4 litre got the shock of his life when he tried to sneak up on the left hand lane at a set of lights only to get blown away by this very ordinary looking Jackaroo. The owner says it also gives V6 Commodores a very hard time.
An added benefit is a reduction in water temps and the exhaust manifold is no longer getting as hot as previously, so obviously the lower intake charge temps are helping here also.
There's just a little heat shielding required on the turbo side to reduce radiated heat from the exhaust manifold. We may possibly run some thermotek padding underneath the shroud over the rocker cover to minimise heat rising from the motor. The shroud can't be seen in the photo's but the air as it goes through the cooler from the bonnet scoop is directed backwards underneath the cooler towards the transmission tunnel. It's very similar to a DTS intercooler setup but even though I happen to be biased, I think mine is better than theirs. 8)

Cheezy, I thought your GQ is a normally aspirated V8.

Stepho, I never really took much notice on hours, it was an interesting technical excercise for me. I do remember however that it seemed to take a longer time than I thought.

Regards Andrew.

Correct me if i'm wrong but i think Cheezy's 'tow truck' is a turbo diesel coil cab therefore the need for the intercooler. Andrew you do very classy work.

Sort of correct Juzza, its a Non turbo diesel 4,2 slug, soon to get a big boost roller bearing turbo and intercooler, new tray, cage, lockers, lift and a shyt load of Cheezy racing products.

Soundin like another race truck Cheezy. Now you'll need another tow vehicle to tow the tow vehicle to tow the Mav????? *HEHE*

Yer for the fast events like Extreem Winch and Outback Challenge, nothing radical so I can still use it as a tow vehicle.

Cheezy4x4 wrote: nothing radical.

I find this very funny coming from Cheezy