Kiwipete's Terrano Intercooler project

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kiwipete
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Kiwipete's Terrano Intercooler project

Post by kiwipete »

It's taken a while, but finialy I have completed this project.

Here is what I started with.
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Lining removed, yet to go back on.
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Topside polished and painted, why? because I could!
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Trial fitting of fan.
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Plummed in, waiting for brackets to be fitted.
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Custom inlet pipe and el cheapo elbow, thanks Tex.
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Measured and re-checked twice and still got it wrong!
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I used Simons idea of sitting the bellows on the intercooler, wetting the top of it and closing the bonnet, leaving a wet guide outline. I then used a cardboard template to mark it out.
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Too late now!
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Bellows fitted, will remove and re-fit when lining goes back on.
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Brackets fitted.
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Bent the brackets in my wood workshop with some angle iron for jaws in my woodwork vice!
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Scoop on. Here i enlarged the front centre hole to allow the fatter plastic part the bolt is on to go through the top skin, the bolt pulls the centre webbing strap tight into the skin on the inside. The rear square centre bolt attachment was fitted through a square hole in the bonnet and fastenend in the same manner as the front one.
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Can you tell the scoop is dark green and bonnet is dark charcoal?
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I also reloacted the diesel filter to the drivers side. It was a tight fit, but worked out well.
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This allows me to move the washer bottle to the firewall, move the air cleaner back and re plumb it directly through the guard to the snorkel, and also fit a 2nd heavey duty battery,
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3 elbows and a inline join saw the inlet plummed to origonal position off the turbo. I did cut the turbo outlet pipe so it was shorter though.
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Just some tidying up of wiring etc and I'm done!.
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Ok people, move along. Nothing to see here. Thank you, move along.
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kbushnz
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Re: Kiwipete's Terrano Intercooler project

Post by kbushnz »

That's a nice clean install... :D
Looks like you had plenty of room to fit it.

Calvin
Cheers Calvin
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kiwipete
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Re: Kiwipete's Terrano Intercooler project

Post by kiwipete »

kbushnz wrote:That's a nice clean install... :D
Looks like you had plenty of room to fit it.

Calvin

Thanks, it was a squeeze, but it did fit well.
Ok people, move along. Nothing to see here. Thank you, move along.
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nzhunter
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Re: Kiwipete's Terrano Intercooler project

Post by nzhunter »

hah good work thats awesome mate, job well done

heck those horns are epic lol
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kiwipete
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Re: Kiwipete's Terrano Intercooler project

Post by kiwipete »

nzhunter wrote:hah good work thats awesome mate, job well done

heck those horns are epic lol

Thanks, yep them horns keep grannies off your bumper. :wink:
Ok people, move along. Nothing to see here. Thank you, move along.
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sibainmud
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Re: Kiwipete's Terrano Intercooler project

Post by sibainmud »

Good install. Keep up the good work :wink:
I keep looking for the loose nut behind the wheel, but I can't find it!!
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Armz
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Re: Kiwipete's Terrano Intercooler project

Post by Armz »

Looks like a nice and tidy job, but how do you plan on topping up the oil??

Also have you had a chance to see what difference its makes???

I was starting to look into doing the same on my Terrano, But a change of plans have seen me sell the truck instead.
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kiwipete
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Re: Kiwipete's Terrano Intercooler project

Post by kiwipete »

sibainmud wrote:Good install. Keep up the good work :wink:

Thanks Simon, couldn't have done it without your help. :wink:
Ok people, move along. Nothing to see here. Thank you, move along.
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kiwipete
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Re: Kiwipete's Terrano Intercooler project

Post by kiwipete »

Armz wrote:Looks like a nice and tidy job, but how do you plan on topping up the oil??

There has to be a trade off as there was no other way I could have done it.
Whe it comes time to change oil, I undo 3 bolts and 2 hose clips and it's off, no real hassle is it?

Also have you had a chance to see what difference its makes???

It is a little peppier off the mark, but I haven't done any proper tests yet.
It's going in for a tune up on Thursday so I realy should notice a BIG difference then.
I did note it lost about 1.5 - 2 PSI of boost with the intercooler on though.
Ok people, move along. Nothing to see here. Thank you, move along.
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sibainmud
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Re: Kiwipete's Terrano Intercooler project

Post by sibainmud »

3 elbows and a inline join saw the inlet plummed to origonal position off the turbo. I did cut the turbo outlet pipe so it was shorter though.


I don't want to be the bringer of bad news, but, those radiator hoses won't have a very long life span with oil laden/hot/boost going through them. They tend to expand and swell then blow up.
I'd give them 6 months or 15,000k's before this becomes a problem. To replace them all to silicone, you'll need sell something, or win lotto :lol:
What boost controller you using?
I can see the similarities to mine, just wish mine was as clean :oops: :oops:
Image
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heck those horns are epic lol

Yeah, are they electric or air?
Best retro fit of a Bighorn Intercooler I've seen :!: :wink: :!:
I keep looking for the loose nut behind the wheel, but I can't find it!!
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kiwipete
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Re: Kiwipete's Terrano Intercooler project

Post by kiwipete »

I don't want to be the bringer of bad news, but, those radiator hoses won't have a very long life span with oil laden/hot/boost going through them. They tend to expand and swell then blow up.
I'd give them 6 months or 15,000k's before this becomes a problem. To replace them all to silicone, you'll need sell something, or win lotto :lol:

Then that's the risk I shall take im afraid, although they are heavy duty ones. I also got them because I could not locate any suitable silicone ones.

What boost controller you using?

No idea sorry, just has a dial and grub screw to set it.

heck those horns are epic lol
Yeah, are they electric or air?

Air

Best retro fit of a Bighorn Intercooler I've seen :!: :wink: :!:

Cheers.
Ok people, move along. Nothing to see here. Thank you, move along.
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Re: Kiwipete's Terrano Intercooler project

Post by Dr Rocket »

Could you tell me what the intercooler came off originally?
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sibainmud
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Re: Kiwipete's Terrano Intercooler project

Post by sibainmud »

Dr Rocket wrote:Could you tell me what the intercooler came off originally?

Mine came off a 97-on Nissan Mistral (the 1 with round headlights).
In other words it came off a TD27.

Cheers,
I keep looking for the loose nut behind the wheel, but I can't find it!!
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Re: Kiwipete's Terrano Intercooler project

Post by flyingbrick »

Painting the intercooler has just made it less efficient.

paint will just help insulate the aluminum from the air thats supposed to be cooling it.
phone Ross Bolus (secretary of the BOP club) He'll save you.
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sibainmud
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Re: Kiwipete's Terrano Intercooler project

Post by sibainmud »

flyingbrick wrote:Painting the intercooler has just made it less efficient.

paint will just help insulate the aluminum from the air thats supposed to be cooling it.


I was going to mension that too, but thought it might not be well recieved after my "radiator hose comment" :?

Cheers.
I keep looking for the loose nut behind the wheel, but I can't find it!!
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Heath
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Re: Kiwipete's Terrano Intercooler project

Post by Heath »

But the fan should improve the flow so it should be better then std.
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flyingbrick
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Re: Kiwipete's Terrano Intercooler project

Post by flyingbrick »

I forgot to add.. Great looking setup 8)
phone Ross Bolus (secretary of the BOP club) He'll save you.
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Re: Kiwipete's Terrano Intercooler project

Post by Smurf »

flyingbrick wrote:Painting the intercooler has just made it less efficient.

paint will just help insulate the aluminum from the air thats supposed to be cooling it.



Not a dig, but why do we paint radiators black?
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sibainmud
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Re: Kiwipete's Terrano Intercooler project

Post by sibainmud »

Smurf wrote:
flyingbrick wrote:Painting the intercooler has just made it less efficient.

paint will just help insulate the aluminum from the air thats supposed to be cooling it.



Not a dig, but why do we paint radiators black?


That was old school :lol: :lol:

Modern ones are bare alloy and plastic tank :!:
Imagine if we painted them white :?: :!: or how many colour coded ones do you see on Boyracer cars?
I keep looking for the loose nut behind the wheel, but I can't find it!!
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flyingbrick
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Re: Kiwipete's Terrano Intercooler project

Post by flyingbrick »

sibainmud wrote:
Smurf wrote:
flyingbrick wrote:Painting the intercooler has just made it less efficient.

paint will just help insulate the aluminum from the air thats supposed to be cooling it.



Not a dig, but why do we paint radiators black?


That was old school :lol: :lol:

Modern ones are bare alloy and plastic tank :!:
Imagine if we painted them white :?: :!: or how many colour coded ones do you see on Boyracer cars?


yeah that was so that they didn't rust and corrode. :lol:
phone Ross Bolus (secretary of the BOP club) He'll save you.
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Smurf
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Re: Kiwipete's Terrano Intercooler project

Post by Smurf »

flyingbrick wrote:
sibainmud wrote:
Smurf wrote:

Not a dig, but why do we paint radiators black?


That was old school :lol: :lol:

Modern ones are bare alloy and plastic tank :!:
Imagine if we painted them white :?: :!: or how many colour coded ones do you see on Boyracer cars?




yeah that was so that they didn't rust and corrode. :lol:



I must be old school then, :oops:
I always thought the black helped with the heat exchange
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kiwipete
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Re: Kiwipete's Terrano Intercooler project

Post by kiwipete »

Dr Rocket wrote:Could you tell me what the intercooler came off originally?

Mine was off a Isuzu Bighorn 3.1TD
Ok people, move along. Nothing to see here. Thank you, move along.
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kiwipete
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Re: Kiwipete's Terrano Intercooler project

Post by kiwipete »

flyingbrick wrote:Painting the intercooler has just made it less efficient.

paint will just help insulate the aluminum from the air thats supposed to be cooling it.

Tell that to the Manufacturer, I just touched it up so im not bothered thanks. It seems to do the job nicely for me and anyway; my truck is a shiny so it suits it eh?
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kiwipete
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Re: Kiwipete's Terrano Intercooler project

Post by kiwipete »

Heath wrote:But the fan should improve the flow so it should be better then std.

I think so too, so much so that its on full time atm.
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kiwipete
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Re: Kiwipete's Terrano Intercooler project

Post by kiwipete »

flyingbrick wrote:I forgot to add.. Great looking setup 8)

Cheers.
Ok people, move along. Nothing to see here. Thank you, move along.
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kiwipete
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Re: Kiwipete's Terrano Intercooler project

Post by kiwipete »

Further to the discussion about the unsuitability of radiator hose for the intercooler, I have had a good friend (Tex) make a custom flange and pipe for me to go on top of the turbo outlet.
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It will replace this factory one,
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By doing this, it will allow me to reduce all the pipework to 2x90deg silicone elbows. Not only will it shorten things up, but it will also get it away from the 2.5 inch turbo dump pipe I had made.
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radar21
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Re: Kiwipete's Terrano Intercooler project

Post by radar21 »

bet she hums along now pete very nice work seen ya the other day going down ferry road i would say you had just knocked off work as it was about 10 past five on friday
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kiwipete
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Re: Kiwipete's Terrano Intercooler project

Post by kiwipete »

Thanks Radar, god knows what I was up to then, :oops: .
Yep she gets off the mark now, I'm dead pleased.
Can even give em boy racers a wee shock too, :lol: but only for the first few seconds, :lol:

Be good to get it out on the trails to see how it preforms, but there is just a couple of mods to go first...............
Ok people, move along. Nothing to see here. Thank you, move along.
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sibainmud
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Re: Kiwipete's Terrano Intercooler project

Post by sibainmud »

kiwipete wrote:Thanks Radar, god knows what I was up to then, :oops: .
Yep she gets off the mark now, I'm dead pleased.
Can even give em boy racers a wee shock too, :lol: but only for the first few seconds, :lol:

Be good to get it out on the trails to see how it preforms, but there is just a couple of mods to go first...............


Looks good Pete. Glad ya went to 2.5 inch all the way from the turbo. They sound and go real good.
Cheers,
I keep looking for the loose nut behind the wheel, but I can't find it!!
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Re: Kiwipete's Terrano Intercooler project

Post by Sketchy_Racer »

Nice Job KiwiPete!

I dont suppose you had a drawing taken of the dump pipe flange where it bolts to the turbo did you? I'm looking at starting mine while work is scarce but I need to keep it driveable so want to build the exhaust out of the truck then take an afternoon to install it.

Cheers,

-Sketchy
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