Offroad-Express

Am looking at installing a front mount Safari intercooler system into my early model 80 series. Its a 4.2 diesel.The only problem I can see is that I also have a trans cooler in front of the radiator and its a 50 fin unit. Takes up about half the front of the radiator. Has anyone fitted one of these units and is it likely to fit with the trans cooler. The other alternative is water injection. Has anyone done this.

Hey,

Or you could go for top mount....

http://www.crosscountry4x4.com.au/produ ... ductid=115

I am looking at one of these for my 80 when the bank account allows...Really nice guys there, and offered me a pretty good discount as im outside of Aus.

Jay

Imho top mounts arn't very effective.esp at slow speeds.

Have you thought about fitting a water to air intercooler.?

crazyclark31 wrote:Imho top mounts arn't very effective.esp at slow speeds.

Have you thought about fitting a water to air intercooler.?

I am currently considering all options so tell me more (pros cons). I'm not keen on a top mount. My main consideration is getting everything to fit. A pre made up kit would be nice but I don't think any are going to fit with my trans cooler. I also have the original electric winch on the front so there's not alot of room. Basically the cooler would have to fit in front of the radiator but only take up one half of the grill width. Not sure if there's anything around like that or even if that size would supply sufficient cooling to make it worthwhile

Intercooler of a xr6 turbo would fit good them, long and skinny

Water and air are very efective for low range and 4wding

Although I had been steering away from a top mount unit it would certainly be easier to fit and after reading all the pros and cons of the different systems I'm starting to think top mount will be the way to go. The only issue I have is cutting a hole in the bonnet for the air intake. Does anyone know if this would need certifying as a modified vehicle.

I could be wrong - but I'm pretty sure the addition of any intercooler requires cert.....

Jay wrote:I could be wrong - but I'm pretty sure the addition of any intercooler requires cert.....

I don't think the addition of the cooler is an issue I think its more cutting through any bonnet supports that would be a concern. I know you can't have any corrosion within 150mm of the bonnet hinges or catch.

Some of the Subaru's have water to air intercoolers that are fairly cheap on tradme and some with all you need.
Intercooler, raditor and pump.

Or check out these kits...

http://www.frozenboost.com

Hey,

I have a '91 80 series. I have just bought a 600x300x75 Intercooler which I'm going to mount in the front. I don't do heaps of offroad work. The only issue (which is a large issue) is getting the pipe work sorted, Im thinking it is going to be a bit of a mission, but I've read that you should get the biggest Intercooler you can fit. There seems to be a few people on the Aussie and ih8mud forums that have front mounts with good results.

I don't have a transcooler, or a winch so this probably won't be an option for you. Some of those top mount kits are expensive! I got mine for well under $200.

Dave

80series wrote:Hey,

I have a '91 80 series. I have just bought a 600x300x75 Intercooler which I'm going to mount in the front. I don't do heaps of offroad work. The only issue (which is a large issue) is getting the pipe work sorted, Im thinking it is going to be a bit of a mission, but I've read that you should get the biggest Intercooler you can fit. There seems to be a few people on the Aussie and ih8mud forums that have front mounts with good results.

I don't have a transcooler, or a winch so this probably won't be an option for you. Some of those top mount kits are expensive! I got mine for well under $200.

Dave

Yea there expensive alright. Can get a front mount one for next to nothing and make up the pipework. I might be better off to change trans oil coolers

Do you do a lot of towing?
If not maybe ditch it altogether?

if you do go top mount then again make sure its a big mofo so you get decent cooling. And if pos fit a good flowing fan underneath so when your crawling up the hills it'll still be a cooler and not a heater from heat soak.

I wouldn't put a smaller transcooler on if already have heat issues with your trans

i would fit a front mount and then redo the transcooler.
top mounts are ok but really need a fan to be effective. if you have water temp issues top mounts can sometimes cause problems as the two airflows can fight against each other.

I don't really have heat issues with it its just the fact that I'm running 35" tyres ( sometimes 37" tyres) & tow a 3500kg boat. Its very slow on the hill climbs and the fact that I've spent $4500 on the trans a while ago I want to look after it. I figured if I can get a bit more power out of the engine I will be able to stay in 4th gear alot longer which will keep the trans temp down. The trans temp light comes on at 300F and goes out again when the trans temp drops to 240F. I figured if I don't let it get over 220F I will be safe. At the moment if it hits 220F I pull over and select low range. This brings the trans temp right back to about 180F. I blew 2 studs off the exhaust manifold the other day using my exhaust brakes so while I've got it apart I'll do a few more mods to it and hopefully make it better.

what about a water to air setup? retro fit a subaru one maybe

MATT4U wrote:what about a water to air setup? retro fit a subaru one maybe

Every set up has its pluses and minisus. I like the idea as its easier to route small water pipes from the front mounted radiator to the intercooler but the other draw back is mounting the intercooler part to tie in with the inlet manifold. Definatly giving it a thought.

im about to look at doing one using a subaru kit, weither I use the subaru intercooler or but one and mod it to take water will depend on fitment e.t.c.
I to like the idea of not cutting stuff up. I'm also going to look a making an adapter to bolt up for the intake instead of cutting the feed pipe up.

MATT4U wrote:im about to look at doing one using a subaru kit, weither I use the subaru intercooler or but one and mod it to take water will depend on fitment e.t.c.
I to like the idea of not cutting stuff up. I'm also going to look a making an adapter to bolt up for the intake instead of cutting the feed pipe up.

Be interested in how it goes.

dunno if its been mentioned.... how about the Bighorn top mounted intercooler into an 80?

I got no qualms about cutting the bonnet away. Is there any reason why the bonnet frame cant stay uncut. Surely enough air is going to get sucked/forced in with the frame still in place. (or is there... dunno really, just putting it out there)

I cut my frames in the center.... They are only there in the middle to support the bonnet skin panel... Usually glued on....
I just glued them back on again.....
WOF man never blinked an eyelid.....

i had a play with the subaru water to air intercooler, it works veary well on the terrano. it a old pic .. its a nissan one now lol

a subaru water cooler is a bit small air flow wise for a 4.2td. from memory there is enough room on the passenger side to fit a water cooler. they are far and away more effecint than a top mount and are the best system for slow speed work.

not really, its more about its ability to exchange the heat, while not ideal, will make a great improvement

I've just had the hood up on my work Hilux (giving the VE a jump start) and got to looking at the intercooler on that. Later today Im going to whip out the tape measure and see what the numbers look like. On the face of it, It looks like a longer pipe is needed to get to the 80 series turbo, and a 90deg elbow for the other side. I never realised the 3.0L intercoolers were so wide.

Hmmmmmmmmm

Methanol-water injection way more efficent than any intercooler,i havent done it on the 1hdt 80series yet but have done on couple of 1kzt and the difference is massive and i have now ditched the intercooler all together no more mud clogging that up..

Pradozzer wrote:Methanol-water injection way more efficent than any intercooler,i havent done it on the 1hdt 80series yet but have done on couple of 1kzt and the difference is massive and i have now ditched the intercooler all together no more mud clogging that up..

details please, you cant have knowledge about such things and not share it lol.

Search coolingmist or devilsown they will fill you in,my kit running now is the cheaper one on a 1kzt prado kzj78 running 25psi boost camed,bigger valves,mechanical pump etc goes good!!

pruggerdore wrote:

Pradozzer wrote:Methanol-water injection way more efficent than any intercooler,i havent done it on the 1hdt 80series yet but have done on couple of 1kzt and the difference is massive and i have now ditched the intercooler all together no more mud clogging that up..

details please, you cant have knowledge about such things and not share it lol.

Pradozzer wrote:Methanol-water injection way more efficent than any intercooler,i havent done it on the 1hdt 80series yet but have done on couple of 1kzt and the difference is massive and i have now ditched the intercooler all together no more mud clogging that up..

the problem is the large amount of water/meth that you go through if your going to use it to replace an intercooler.

i would intercool if you can. intercooling works all the time. if its still not cold enough you can add water/meth injection.

Early Subie wtair were disigned to wk with 150kw reliably, the "late" model TT 206kw ones shd cover your requirments parts are common etc. Make sure you get all the bits required - google how they wk for a complete list so you dont have to chase them later.

Yes water to air is a more complex setup but shorter inlet tract easier to plumb up in tight aeras and wk better at lower vehicle speeds.

Menthol inj came out in piston planes and frd mercuarys I think, the setup is well proven. Water mist on the heat exchanger also wks well,a cheap setup can be driven off an extra window washer motor