some new upgrades

[jessef]

First intercooler I've seen with pipping on one side.

May make for a clean install.

[garyo]

looks like a 240 nissan. lots of these around cheap.

[jessef]

Good eye

[mararmeisto]

Why does it look like the car was found upside down in a mud puddle? Are you going to be able to clean all of that gunk out of the fins? Nice find.

Will have to watch where you stuff it so I can take notes...

[jessef]

I didn't buy it. Just looking for different routing/mounting options.

[Golf Cart]

Name that Intercooler

Quite a few for sale these days.

Garyo - R32 correct ?

[mararmeisto]

I like the one Jesse found - I think that would work really well.

Garyo: for someone who does that sort of thing for a living, how long would it take them weld/bend up some tubing? Do you think there would be enough room on the one side to squeeze both pipes in (using the intercooler with inlet and outlet on the same side)?

Finally, when you removed the EGR, where does that feed into, and can it just be replaced with a hunk of straight pipe? I see some over-the-water talk of blanking it off. Wouldn't adding exhaust to the turbo be the 'wrong' thing to do? I understand it's supposed to allow for the 'reburning' of unspent fuel, but it seems more counterproductive than beneficial.

[delicat]

Jesse,

That's one style of intercooler I was referring to but I'm pretty sure I've seen them where both In/Out are on the same end tank (like the intercooler is cut in half lenght wise, air goes in at bottom, turns around at opposite side and comes back through upper part of intercooler to Out pipe) I like that style as it's even more compact.

J. Paul,

Something else to consider when building an intercooler is the pipe material. I've read a recent article where they were using copper piping commonly found at the plumber store. Cheap, nice clean radius, comes in different diameter (2", 2 1/2"...) and easy to set up as they have couplings to insert into each ends. Also dissipate heat better... A little more fragile but route pipes accordingly. I'd consider this option quite seriously. Innovative!

[Jaz]

Funny you should mention that David... I think we need to chat.





Here's my last project, with 2" hot side and 2.5" cold side, fitted to a 600x300 intercooler hanging out the front.

Put it in with the help of the Father Out-Law, and it's actually interesting to work with - It's quite flexible after it's been silver soldered, so you can actually tweak a bit more into the bends if it doesn't quite line up properly, or straighten it out. It's also really easy to do - he worked with the stuff day in day out, so I had free gas and free silver solder, and he got me a decent price at the plumbing shop for the pipes. It's kind of like putting together a mechano (did you have that stuff) set, where you can line it all up, then just solder it together.

Not sure if I'd do it again that way, because it ended up costing me the same as it would have for a stainless job, but I'd actually intended to get it dipped to bring it up to a nice shine... would have been cool.

The way to do it though, is how a friend of mine did it - he picked up a bunch of copper piping and bends at a clearing house for nix - free front mounted intercooler! He also wrapped his piping with heatwrap to decrease engine temps, which might be an idea with the delicas if possible.

As for being fragile, I wouldn't worry about that, I frigged around with mine enough and never had any problems!

In my previous life I had a fair bit to do with ponderations about intercoolers, and lots of useful tech info was thrown around the forum I used to hang out at. I think we need to catch up for coffee sometime David, I have some thoughts about mounting the cooler in a different spot to normal, and wouldn't mind a poke around your van... and no, it's not on the roof!


EDIT: Ha, just found one alternative...

[garyo]

To answer Mararmeisto`s question, more money thrown at it would make life a lot easier. Davids sugestion to replace the rad with a smaller but thicker one, then run an electric fan was a great idea, but more expensive. I kinda wanted to do it super cheap.
I`d make the rad narrower, not shorter. there`s not enough room beside it to run 2 pipes. 3-4 inches narrower, then push it as far as possible to the passenger side. this would allow you to run both pipes straight forward off the turbo and to the intake manifold. going out the fenderwell ads a lot of work and has to replace the intake tube that brings fresh air to the filter ( i`ll be running a snorkel so that tube doesnt matter on mine). the hose for the stering pump is still in the way.would have to make a new hose with a different end. but you then wouldn`t have to rotate the air filter,cut and reweld the intake pipe, and cut the body for clearence. ( david, I cut out where you sugested )

I removed the egr w/ the pipe from he exhaust manifold, then made a block off plate at the manifold. my theory is the more exhaust going thruogh the turbo the better. the wastegate wouldn`t let it over boost. the more clean air going into the engine, the better the potential for more power. thats what this was all about anyway.

the egr is not about burning unburnt fuel, it`s job is to introduce an inert gas into the combustion chamber, lowering temps w/ reduces nox.

got a bit of abuse from some friends about having the cooler out front all exposed. not now.

[Chewy]

I have some Ideas for a front mount that sits behind the bumper but with some ducting that hugs close to the front bumper. I'll be under mine looking for room tomorrow.

[garyo]

Hot rod Delica`s , who would have thought?

[delicat]

Good tips Gary, nice to see the cage all finished under...
Running just under 12psi now , makes a nice difference! Thanks again!!!

Jaz, Nice set up! Surprised the cost was the same as stainless... I'm sure with SS cost would have added up at the end and you still ended up with a much better price though. Ok, going hunting for a kitchen pass so we can hook up for coffee, Deanna is going crazy with me as I'm out every single day working on my truck!

[after oil]

yesterday a guy with a big chev diesel showed me his "air cooler" he simply got rid of all the air filter housing and mounted a huge washable air filter, separated from the rest of the engine by a heat shield. he said that reduced the air restriction enough thus allowing more cool air, and claims to have gained 15hp.
my initial thought, if applied to the delica, is that a filter w/o a can on it would be to exposed to water if going in a deep puddle. the filter would have to be moved...

[Jaz]

David, I guess I should have mentioned that all the welding etc would have been free too with stainless, so it was just the basic materials cost. Still, all up including the cooler it only cost me about $450.

I'm always up for a tinker with a vehicle, so give me a bell some time if you want/need a hand fettling with the bus! That reminds me, this weekend I have to find out why the Prawn sounds like a German Stuka at full dive on startup occasionally... fun fun fun!