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Post by dasnoboarder on Jun 23, 2008 17:13:00 GMT 11
Hey guys. Thought I'd do a write up on what I've done with my intercooler. First off, the intercooler is made from the factory end tanks off a bighorn cooler and a custom bar & plate core, welded up by Jarrad from Turbocharger Reconditioners (same place I got my turbo made up). After talking to a few people, it was obvious that to rotate the turbo safely, it would need to be taken off the car ...that was great news haha. I had the aircon purged and took off the major interfering pipes before attacking the turbo. Managed to take out quite a few pipes from the aircon, and the condensor, so now there is a lot more airflow to the radiator. Also changed my glow plugs when everything was off. Here's some pics:    It's still sitting in the garage. I think one of the pipes is leaking air, so will have a look at that tonight. I am leaving it as is for now, will hopefully get a bonnet scoop and put it on within the next few weeks. Then after a body lift, I'll put a electric fan on top of the cooler. It just touches the bonnet matting as is, but vibrates quite a bit at low revs and stat-up/shut-off. P.S. Check out the new Rhino Aero racks!   Andy. ;D . |
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Post by holden on Jun 23, 2008 17:19:40 GMT 11
Nice  Where you gonna get a body lift from hint hint  |
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Post by dasnoboarder on Jun 23, 2008 17:23:44 GMT 11
Nice Where you gonna get a body lift from hint hint Msn mate  . |
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Post by geeves on Jun 23, 2008 18:52:48 GMT 11
tidy job
the intercooler wont do anything until it has a source of cold air ie scoop. It might even end up heating the air further
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Post by dasnoboarder on Jun 23, 2008 19:04:51 GMT 11
tidy job the intercooler wont do anything until it has a source of cold air ie scoop. It might even end up heating the air further Hmmm I didn't think it would do much as is. I'll get on to finding the scoop I want asap... Bit worried about taking the angle grinder to the bonnet tho... |
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Post by add400 on Jun 23, 2008 20:10:33 GMT 11
come on it didnt hurt that much ;D  |
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Post by dasnoboarder on Jun 23, 2008 20:14:37 GMT 11
come on it didnt hurt that much ;D Haha the grinding would be an experience, but thinking I might get a panel beater to cut the hole and primer & paint the lip & the scoop the right colour... We'll see how much the quotes are... |
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gecko
Isuzu Junior
Posts: 92
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Post by gecko on Jun 24, 2008 1:22:28 GMT 11
nice clean looking setup
cutting the hole in the bonnet is easy, im a measurement guy, i measured, remeasured and measured some more, then i cut it out in one go with a very thin metal cut off disc, if you take it easy you wont blister the paint around the hole much, my mate cut a hole in his aswell but his tecnique was to cut a small hole, see what its like then make it bigger, my way was alot cleaner and simpler in the end.
matching the paint is the fun part, my bonnet is slightly faded, but no one would know unless i said something.
i did mine myself to cut costs down and becasue now ive done it once i can do it again no problem.
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Post by dasnoboarder on Jun 24, 2008 19:34:08 GMT 11
Haven't received a reply from the wreckers yet...
Have got it running finally! Makes a whole lot more noise/turbo whine.
Had to put some sealant between the piece of the intercooler that connects to the turbo and the core, and do some more tightening of bolts as it was leaking exhaust, making an awful sound.
It might still be leaking exhaust a tad from somewhere, but will observe over next few days...
Feels faster, but as said, I think the cooler heats up after a while.
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Post by powertruck on Jun 24, 2008 21:42:13 GMT 11
hi andy did you find a exhaust leak in the end?
Sounded to me like you had a manifold leak somwhere.
When you get your scoop sorted you will notice a big difference
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Post by dasnoboarder on Jun 25, 2008 16:03:54 GMT 11
Yea we fixed that squealing noise somehow, the two top bolts from turbo to exhaust manifold wernt tightend enough. We double tightend the rest while we could get at them with the cooler off. I think it might still have a tiny exhaust leak, or it could still be burning wd-40 off the manifold and exhaust. The top oil line was leaking a bit, so nipped that up some more... One wrecker didn't have the scoop I'm looking for, still waiting for a reply from the other one. So far I'm most impressed by the noise it makes! Here's what we got up to with the new set-up today:  |
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Post by dasnoboarder on Jun 26, 2008 18:59:08 GMT 11
Got the scoop today.
It's from an early Bighorn model (88,89,90). It looks like we're gonna have a go at the bonnet cutting too. Then after it's all done, get it colour matched as it's white at the moment.
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Post by add400 on Jun 26, 2008 19:26:13 GMT 11
there not a bad scoop, they push a gut load of air to the intercooler. time to grab the grinder.. hehe
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Post by holden on Jul 2, 2008 7:05:47 GMT 11
CUT the hole yet  |
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Post by dasnoboarder on Jul 2, 2008 7:15:23 GMT 11
Right, so we're all done. In the process I've found a new love for angle grinders, much better than a hacksaw. My $15 100mm grinder with grinding wheel and $5 cutting wheel did the job quite nicely ;D . Drilling the holes for the scoops bolts and making enough room to put the nuts in through the ribbing took as long as cutting the large hole for the rubber boot (which had to be modified as I didn't want to relocate the windscreen washers). Here's the top hole for the rubber boot all done (vivid yet to be cleaned off).  All fitted up, you can see my generous primer applications:  Still in the garage, haven't been out in it yet. Will get some proper photos, but here it is:      It seals very well on the right hand side. but has a small gap in the left and at the back. I'll probably get around to putting some sealant in there sometime. Also the front does not sit completley flush, maybe 5mm between it and the bonnet in the center, I might seal this down, but doesn't bother me at the moment. |
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Post by geeves on Jul 2, 2008 9:16:53 GMT 11
nice job. Good to see the colour match as well. A lot of the others Ive seen are still the original colour or worse mat black
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Post by dasnoboarder on Jul 2, 2008 11:04:42 GMT 11
nice job. Good to see the colour match as well. A lot of the others Ive seen are still the original colour or worse mat black Thanks Geeves. I thought it would be best to do the colour match, don't want to take it off again for a long time, hopefully never. The only problem is that the scoops paint looks so good I want to re-do the whole thing now! |
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Post by powertruck on Jul 4, 2008 20:42:45 GMT 11
hey Andy when you cut your hole in your bonnet did you cut it to the bighorn size hole?
The scoop on the bighorns is much bigger than the hole where it lets air into the intercooler
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Post by dasnoboarder on Jul 4, 2008 20:54:46 GMT 11
hey Andy when you cut your hole in your bonnet did you cut it to the bighorn size hole? The scoop on the bighorns is much bigger than the hole where it lets air into the intercooler Hey. I have the early bighorn scoop which is quite a bit larger than the next generation of bighorns. We cut the hole to suit the rubber boot that came with the scoop. Our first hole we cut was about half the size that we needed. We then put the bonnet back on the truck and marked out with a vivid how far in each direction we needed to go to centre the hole over the intercooler. The boot fits over an area just larger than the intercooler. My boot and scoop are not connected to each other in anyway, so if the later bighorn's rubber boot is different, I could have used that just as easily. Was a long process of testing and re-marking, but a fun mod. |
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Post by powertruck on Jul 4, 2008 20:59:17 GMT 11
I'm lookin for a 2nd hand bonnet im going to re-do my one with a scoop off a 95 bighorn
Hows the truck going now that you have the scoop in it?
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