TD27T power

[passengerpete]

Did a few mods to my td27t [img][img=http://img199.imageshack.us/img199/3576/img0056hbr.th.jpg]
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[kiwipete]

How do you find the performance now?
I like the way you did the exhaust manifold outlet for the larger pipe. What size is it and do you have a template for it?
What intercooler did you use?

[passengerpete]

the intercooler is a rx7 s4 $60 off trade me. about 1989-1991 i think.The down pipe is 2.5'' and required a wee bit of thought as i had never came across a turbo with the waste gate on top of the exhaust wheel before so just turned it around 90 degrees then had a few goes at getting the pipe radius right because there is not a lot of space in a d21.I'm glad i did because well worth the effort.it was like i put a big bore exhaust on a gain. All of the big bore exhaust i have seen on wd21 only start from that stupid cast turbo outlet so it needs to go imo.
as for the intercooler. i did this before the exhaust and the results where unexpected as i felt nothing at all power wise but i did notice that it stopped the puffs of black smoke from the exhaust and i could maintain same speeds with less throttle so was more economical.

[kiwipete]

This is the intercooler setup im looking at doing. This setup is on a TD4.2 tho, but should still work in principle.





He used a Repco intercooler for this project.

What thickness plate is that you used for the exhaust outlet? It's gotta be one of the best ideas I have seen yet.

What did you use for a bonnet scoop? I hear Bighorn are the ones to look for.

[passengerpete]

That intercooler may be i bit long for a wd21 unless ya offset it ? might foul on the clutch reservoir maybe. the plate on dump pipe is 10mm will add more pics for ya.
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[kiwipete]

Mines an auto so I do not think there will be a problem with the length of the intercooler.
Did you make and weld the dump pipe yourself?

[passengerpete]

i welded up the exhaust but a mate did the dump pipe as my mig was playing up.
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[passengerpete]

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[passengerpete]

I don't have a template for the dump pipe sorry as we kinder just winged it till we had something that fitted and flowed has much as it could. its basically a flange cut out of 10x80mm flat bar with bolt holes lined up then drilled. then two 63mm holes cut into it with one overlapping. the pipe is 1.6mm wall 90degree exhaust bend cut down too suit with the off cut going on top for the wastegate.
i could get more made if there is enough interest maybe. but if ya can weld its a fun wee project.

[kiwipete]

I would be interested in a price for one please. My welding looks like chook poop.

What diameter pipe is it?

[marmel]

I would be a definite starter for a pipe as well if you get any made.

[passengerpete]

pipe is 2 1/2'' and was the biggest i could go without running into trouble with the bolt holes as it is i run m8 cap screws to save space, its a pain to tighten up but you only do it once.i will price things up next week and see if its cost effective

[kiwipete]

Last question for a bit, what scoop did you go for? Any pics?

[passengerpete]

the scoop i used was just of trade me it has not truned up yet so cant tank any pics, what i've done in the mean is just sooo ranigi it not worth taking pics of think angle grinder and pull the boonet up

[long]

Im keen on one as well

[passengerpete]

can build the dump pipe for $230 each. who still wants one.

[kiwipete]

Sorry, im a little shy at that price sorry, im out. Do you have a pattern/measurements of the flange at all?

[long]

Im with him ^^^^^^

[passengerpete]

will post up flange dimension's for ya.
it was not cost effective to go under $190 so that's where the price came from. the cheapest place for bends i found was Chase in ch ch. bar from steel and tube 8m lengths so ya need a Ute or get it cut.

[kbjj]

If you want more hp, try this. I was told the td27 can happily put up with 15-16psi boost, as long as you dont exceed 850-900 degrees C in exhast manifold. So... I brought a EGT guage from moonlight racing (google it) for $142 on my door step, then increased boost to 15psi which means more air, meaning I can add more fuel which equalls more hp. Add too much fuel and EGT is too high ie: damage will occure. Guage is cheap insurance on motor life. It is a different truck to drive, I'm loving it. More hp = more fuel = less economy, but you get there quicker You are probabaly noticeing better economy as its leaned motor slightly due to more air (cool air = more air), therefore less black smoke unburnt fuel. After my we mod, I get black exhaust when low reving under load with my foot up it. I only screewed mix in about a quater turn if that. I did this so I have my hp at slow speeds, wereas an intercooler needs airflow.
I like your exhaust/turbo dump pipe. Mines 2.5 inch from factory flange onwards. I might copy your idea. Good job

[kiwipete]

will post up flange dimension's for ya.
it was not cost effective to go under $190 so that's where the price came from. the cheapest place for bends i found was Chase in ch ch. bar from steel and tube 8m lengths so ya need a Ute or get it cut.

Did you manage to get those dimensions at all?

[sibainmud]

Nice mods guys!!!
As kiwi Pete knows, At flat out my boost gauge reads just short of 20psi, on the road going up hills, I just lift my foot slightly to about 15psi. i have standard exhaust and no intercooler. i have a "doner" intercooler off a R32 Skyline but haven't fitted it yet, because there is an easier option. 97-on Mistral's are factory intercooled TD27's. I have found one at a wreaker and it bolts straight on to turbo and intake manifold. I have disconnected the actuator hose to wastegate diaphram, and removed relief valve from intake manifold. The relief valve used to "blow-off" at 13psi.
Most of the time, I run a pod filter fastened straight to the turbo,
works good and sounds awsome! When it is wet or doing deep water, i fit up the snorkle with a small pipe I keep in the back.
I found the snorkle was restrictive. When i fitted the snorkle, i neglected to use the supplied "S" bend through front of the gaurd. Instead, I hole-sawed a hole through inner gaurd opposite the hole in outter gaurd and connected a hose onto snorkle and through this hole almost direct to turbo. When I connect snorkle, I move pod filter from turbo to the top where the scoop is, fit my link pipe, and it's all done!
I'm going to opt for 2.5+ inch exhaust from first flange back like you other guys, but I'm still deciding. i may be in the market for one of those custom dump pipes yet.
I will try post some pics tomorrow night, and I dare say, i will have much more to comment on this subject.
Cheers for now.

[kiwipete]

Yep, one of those '97 Mistral intercoolers is just what I'm after as well as the bonnet rubber gasket. I need to do some searching of the wreckers now.

[sibainmud]

Yep, one of those '97 Mistral intercoolers is just what I'm after as well as the bonnet rubber gasket. I need to do some searching of the wreckers now.

The guy I meet running 22psi, his Dad owns a wreaker up here in Auckland, and he reckons he's got a couple of them spare. I'll check it out next week and let you know of the cost and availiblity.
Cheers.

[kiwipete]

Yep, one of those '97 Mistral intercoolers is just what I'm after as well as the bonnet rubber gasket. I need to do some searching of the wreckers now.

The guy I meet running 22psi, his Dad owns a wreaker up here in Auckland, and he reckons he's got a couple of them spare. I'll check it out next week and let you know of the cost and availiblity.
Cheers.

Appreciate that, thanks.

[kbjj]

Is there any use running an intercooler offroad at lowspeeds My understanding is intercoolers need good airflow to be of any real advantage. I understand getting to your favourate track quicker is fun to

[sibainmud]

I was thinking of "shoe-horning" a fan in too. Of the opinon that any cooler is better than none at all.
Cheers.

[kiwipete]

As Simon said, you place an electric fan on top of the intercooler for added cooling when at low speeds, any small advantage is better than none IMHO.

[kbjj]

I like the attitude. Every little bit helps. This Mistral idea sounds good. I was looking at a Bighorn intercooler, boot and scoop. IMO I believe a fan is nessasary, at low speeds, (especially when bellied in a mud hole) to stop engine bay heat heating the intercooler.

[sibainmud]

Nice mods guys!!!
I will try post some pics tomorrow night, and I dare say, i will have much more to comment on this subject.
Cheers for now.

Ignore the dirt on Air-cleaner, just came from dusty day at Woodhill.