Intercooler Pics
- dandjcr
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31 Dec 2012 06:43 #1
by dandjcr
David and Janet Ribbans - Oka 148
Oka148 profile here.
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dandjcr created the topic: Intercooler Pics
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Outback Jack
Member
Posts: 391
Hi All,
Does anyone have some pictures of Intercooler Installs???? Or perhaps part numbers etc etc?
Being in the middle of nowhere, means I just cant go down the street to by bends, pipes etc. Just installing the new Aircleaner has takening a month of ordering bits and pieces. Just about finished with it.
So if funds permit, I am thinking of installing a Intercooler
--
October 27, 2012 at 7:59 AM Flag Quote & Reply
Dandj
Member
Posts: 367
OBJ , there have been several posts (no longer accessible) with intercooler pics and info.
I'll compile and post some here from my archives later today. There's some pics of Oka 224's air/air intercooler to start with here. A glycol/air intercooler would probably be preferred these days.
--
David and Janet Ribbans, Oka 148
October 27, 2012 at 6:46 PM Flag Quote & Reply
Outback Jack
Member
Posts: 391
Cheers David,I did a search with Google, I did come up with some pics, but nothing to detailed.
I am not sure about the gycol intercooler, a lot more work required for the little gain.
--
October 27, 2012 at 7:49 PM Flag Quote & Reply
Outback Jack
Member
Posts: 391
Link appears to be broken
--
October 27, 2012 at 8:11 PM Flag Quote & Reply
Dandj
Member
Posts: 367
OBJ, the link works for me. The document is in Home Page/Documents and Data/Forum Listings.
Bear in mind this website is a bit flaky right now since it had a major internal software fault a couple of weeks ago which destroyed all the forum posts and videos. We are working on the plan ahead.
--
David and Janet Ribbans, Oka 148
October 27, 2012 at 8:45 PM Flag Quote & Reply
Outback Jack
Member
Posts: 391
HI David,
Its still broke for me, I will try different computer tommorrow.
Thks for all your efforts
--
October 28, 2012 at 3:35 AM Flag Quote & Reply
Dandj
Member
Posts: 367
OBJ, my apologies, the link IS broken, and i've made several other unsuccessful attempts to re-upload it. It must be the flaky website since it uploads to Scribd fine and you can view it and a few other intercooler related posts at this link.
Let me know if this fails too.
--
David and Janet Ribbans, Oka 148
October 28, 2012 at 4:13 AM Flag Quote & Reply
Outback Jack
Member
Posts: 391
Thanks David, that works. I had never seen those pictures before.
I was wondering if you could mount a small glycol/air intercooler like you mentioned on the back firewall above the engine or somewhere there. Then mounting the radiator vertical under the bus body? Less hoses etc etc.
I am sure there would be a bit of loss running all the way to the front and back.
My intake pipe is 4 inch now, with the airfilter having 5 inch inlet and outlets.
--
October 28, 2012 at 4:35 AM Flag Quote & Reply
Dandj
Member
Posts: 367
OBJ, yes and it has been done. Tim Forsyth fitted a large (and expensive) intercooler above the rocker cover on his Oka 072 (now owned by James&Usha). See Tims' article on his website.
Shorter air pipes mean less latency from the turbo and larger pipes allow better airflow. We don't have one yet but I am thinking in that direction.
You might also contact Denco Diesel who manufacture intercoolers, or truck wreckers who might have something of the right dimensions.
--
David and Janet Ribbans, Oka 148
October 28, 2012 at 5:02 AM Flag Quote & Reply
Outback Jack
Member
Posts: 391
Yes have seen Tims, and seem a little over the top, pardon the pun.
My thoughts is to mount something smaller on the back firewall. They dont have to be that big I dont think.
Then I would mount a small radiator under the bus body.
Just a thought and thinking out aloud.
--
October 28, 2012 at 6:22 AM Flag Quote & Reply
Peter Davis & Serena Fraser
Member
Posts: 39
I mounted a water/air intercooler between the battery and mudflap on the drivers side. I put the radiator with thermo fan between the fuel tank and front mud flap of the rear drivers side wheel on about a 45 deg angle. It made a big difference to the truck power wise, but I think the fuel economy went down. It cost me about $1000. The dearest parts are the silicon hoses and clamps. I put the intercooler below the level of the engine air inlet in case it developed a water leak which could go into the engine. It was a fiddly job but I didn't need to alter anything to make it fit and I can reasonably quickly bypass the intercooler if need be. I hope this is of assistance.
--
October 28, 2012 at 7:58 AM Flag Quote & Reply
Outback Jack
Member
Posts: 391
Hi Peter,
Thats sound great, any chance of some pictures, part numbers?
Maybe the fuel pump needs to be adjusted afterwards.
I have just installed an Optiair 1100 airfilter. Sounds a lot better and I think will flow better. It was a bit of a battle and I used several silicon adapters, 4 inch pipe to intake etc etc.
--
October 28, 2012 at 8:19 AM Flag Quote & Reply
Dandj
Member
Posts: 367
OBJ, do you have a pics of your Optiair installation. I'm planning the same upgrade soon.
And Peter, yes your intercooler installation is also of interest.
Regards.
--
David and Janet Ribbans, Oka 148
October 28, 2012 at 11:01 PM Flag Quote & Reply
Outback Jack
Member
Posts: 391
I will post some pictures up tonight on my photobucket account.
I think you could do it for well under 1k. Being in the bush, I had to pay freight etc etc. I also had to buy extra bends, reducers etc because I wasn’t really sure how I was going to do it.
Here is how I basically did it. Pictures will help later.
Air cleaner Outlet into Turbo
I used the existing bend that use to go into the old aircleaner. It has a 3 inch ID. I used a 4 inch to 3inch reducer to bolt onto that. I then used 4 inch aluminium pipe as joiner. On the air cleaner it is 5inch , so again used a 5 inch to 4 inch reducer, this was connected to the 4inch aluminium pipe.
Inlet
I used a 90 degree 5 inch to 4 inch reducer on the air cleaner inlet. I then used 4 inch Aluminium pipe as joiner and at the other end put a 4 inch to 4 inch 90 degree elbow. Then up to the intake scoop is 4 inch pipe, finally at the end is another 4 inch to 4 inch 90 degree elbow. I havent got that elbow yet.
The area behind driver’s seat had to be cut out, as the 90 degree elbow is higher. I still need to make a top cover for that.
I used the original mounting brackets for the vertical pipe, just needed to cut out the brackets to suit 4 inch pipe.
I had to cut off a support and mount it higher.
That’s about it.
If I was in the big smoke, I think it would only take a day or two at the most………
Here is a picture of the original set up and what I had to do.
Notice all the rust…. On the passenger side, there was virtually none. I think the old snorkel must have let water get in between the panels.
--
October 29, 2012 at 12:45 AM Flag Quote & Reply
Outback Jack
Member
Posts: 391
More Pictures on the following Photobucket site
photobucket.com/oka169
and here
s1256.photobucket.com/albums/ii494/ntexp...%20Under%20Carriage/
--
October 29, 2012 at 4:49 AM Flag Quote & Reply
Moose2367
Member
Posts: 113
The optiair is also a mod going in mine, as the Cummins needs a lot more air than the Perkins did. Pretty sure i can get away with the 1000 model, but might go the 1100 seeing as it can be done while the cab is off.
The Perkins was sold this week too, woohoo, just the gearbox and wheels now.
October 29, 2012 at 6:22 AM Flag Quote & Reply
Outback Jack
Member
Posts: 391
Yes there is calculators onsite, cant remember where. But think the Perkins needs around 650 CFM flow for memory. So the Optiair 1100 works great. It is around that figure, maybe a little higher. However with my reducers etc, I am hoping it will balance out.
--
October 29, 2012 at 7:11 AM Flag Quote & Reply
Peter Davis & Serena Fraser
Member
Posts: 39
If I find some pictures I'm happy to post them. Off the top of my head the bosch water pump was about $100, the radiator with thermo fan was from a daihatsu at the wreckers for $120, the intercoooler was about $130. The intercooler had 3" input and output air flow with roughly dimensions 300 x 300 x 3".There are bigger intercoolers but they won't fit where I put it. I put the overflow bottle in the engine bay and a filling point. I used 1" stainless steel or alloy pipes for the water with rubber hoses for bends. I mounted the water pump under the battery directly in line with the bottom of the intercooler. I installed a couple of bleed points, an air scoop in front of the radiator and low coolant alerts for both the intercooler radiator and normal radiator. If you haven't already install a pyrometer, the temperatures obtained are quite scary esp without an intercooler. It is also the best way to judge when to turn the engine off.
--
October 29, 2012 at 8:05 AM
Outback Jack
Member
Posts: 391
Hi All,
Does anyone have some pictures of Intercooler Installs???? Or perhaps part numbers etc etc?
Being in the middle of nowhere, means I just cant go down the street to by bends, pipes etc. Just installing the new Aircleaner has takening a month of ordering bits and pieces. Just about finished with it.
So if funds permit, I am thinking of installing a Intercooler
--
October 27, 2012 at 7:59 AM Flag Quote & Reply
Dandj
Member
Posts: 367
OBJ , there have been several posts (no longer accessible) with intercooler pics and info.
I'll compile and post some here from my archives later today. There's some pics of Oka 224's air/air intercooler to start with here. A glycol/air intercooler would probably be preferred these days.
--
David and Janet Ribbans, Oka 148
October 27, 2012 at 6:46 PM Flag Quote & Reply
Outback Jack
Member
Posts: 391
Cheers David,I did a search with Google, I did come up with some pics, but nothing to detailed.
I am not sure about the gycol intercooler, a lot more work required for the little gain.
--
October 27, 2012 at 7:49 PM Flag Quote & Reply
Outback Jack
Member
Posts: 391
Link appears to be broken
--
October 27, 2012 at 8:11 PM Flag Quote & Reply
Dandj
Member
Posts: 367
OBJ, the link works for me. The document is in Home Page/Documents and Data/Forum Listings.
Bear in mind this website is a bit flaky right now since it had a major internal software fault a couple of weeks ago which destroyed all the forum posts and videos. We are working on the plan ahead.
--
David and Janet Ribbans, Oka 148
October 27, 2012 at 8:45 PM Flag Quote & Reply
Outback Jack
Member
Posts: 391
HI David,
Its still broke for me, I will try different computer tommorrow.
Thks for all your efforts
--
October 28, 2012 at 3:35 AM Flag Quote & Reply
Dandj
Member
Posts: 367
OBJ, my apologies, the link IS broken, and i've made several other unsuccessful attempts to re-upload it. It must be the flaky website since it uploads to Scribd fine and you can view it and a few other intercooler related posts at this link.
Let me know if this fails too.
--
David and Janet Ribbans, Oka 148
October 28, 2012 at 4:13 AM Flag Quote & Reply
Outback Jack
Member
Posts: 391
Thanks David, that works. I had never seen those pictures before.
I was wondering if you could mount a small glycol/air intercooler like you mentioned on the back firewall above the engine or somewhere there. Then mounting the radiator vertical under the bus body? Less hoses etc etc.
I am sure there would be a bit of loss running all the way to the front and back.
My intake pipe is 4 inch now, with the airfilter having 5 inch inlet and outlets.
--
October 28, 2012 at 4:35 AM Flag Quote & Reply
Dandj
Member
Posts: 367
OBJ, yes and it has been done. Tim Forsyth fitted a large (and expensive) intercooler above the rocker cover on his Oka 072 (now owned by James&Usha). See Tims' article on his website.
Shorter air pipes mean less latency from the turbo and larger pipes allow better airflow. We don't have one yet but I am thinking in that direction.
You might also contact Denco Diesel who manufacture intercoolers, or truck wreckers who might have something of the right dimensions.
--
David and Janet Ribbans, Oka 148
October 28, 2012 at 5:02 AM Flag Quote & Reply
Outback Jack
Member
Posts: 391
Yes have seen Tims, and seem a little over the top, pardon the pun.
My thoughts is to mount something smaller on the back firewall. They dont have to be that big I dont think.
Then I would mount a small radiator under the bus body.
Just a thought and thinking out aloud.
--
October 28, 2012 at 6:22 AM Flag Quote & Reply
Peter Davis & Serena Fraser
Member
Posts: 39
I mounted a water/air intercooler between the battery and mudflap on the drivers side. I put the radiator with thermo fan between the fuel tank and front mud flap of the rear drivers side wheel on about a 45 deg angle. It made a big difference to the truck power wise, but I think the fuel economy went down. It cost me about $1000. The dearest parts are the silicon hoses and clamps. I put the intercooler below the level of the engine air inlet in case it developed a water leak which could go into the engine. It was a fiddly job but I didn't need to alter anything to make it fit and I can reasonably quickly bypass the intercooler if need be. I hope this is of assistance.
--
October 28, 2012 at 7:58 AM Flag Quote & Reply
Outback Jack
Member
Posts: 391
Hi Peter,
Thats sound great, any chance of some pictures, part numbers?
Maybe the fuel pump needs to be adjusted afterwards.
I have just installed an Optiair 1100 airfilter. Sounds a lot better and I think will flow better. It was a bit of a battle and I used several silicon adapters, 4 inch pipe to intake etc etc.
--
October 28, 2012 at 8:19 AM Flag Quote & Reply
Dandj
Member
Posts: 367
OBJ, do you have a pics of your Optiair installation. I'm planning the same upgrade soon.
And Peter, yes your intercooler installation is also of interest.
Regards.
--
David and Janet Ribbans, Oka 148
October 28, 2012 at 11:01 PM Flag Quote & Reply
Outback Jack
Member
Posts: 391
I will post some pictures up tonight on my photobucket account.
I think you could do it for well under 1k. Being in the bush, I had to pay freight etc etc. I also had to buy extra bends, reducers etc because I wasn’t really sure how I was going to do it.
Here is how I basically did it. Pictures will help later.
Air cleaner Outlet into Turbo
I used the existing bend that use to go into the old aircleaner. It has a 3 inch ID. I used a 4 inch to 3inch reducer to bolt onto that. I then used 4 inch aluminium pipe as joiner. On the air cleaner it is 5inch , so again used a 5 inch to 4 inch reducer, this was connected to the 4inch aluminium pipe.
Inlet
I used a 90 degree 5 inch to 4 inch reducer on the air cleaner inlet. I then used 4 inch Aluminium pipe as joiner and at the other end put a 4 inch to 4 inch 90 degree elbow. Then up to the intake scoop is 4 inch pipe, finally at the end is another 4 inch to 4 inch 90 degree elbow. I havent got that elbow yet.
The area behind driver’s seat had to be cut out, as the 90 degree elbow is higher. I still need to make a top cover for that.
I used the original mounting brackets for the vertical pipe, just needed to cut out the brackets to suit 4 inch pipe.
I had to cut off a support and mount it higher.
That’s about it.
If I was in the big smoke, I think it would only take a day or two at the most………
Here is a picture of the original set up and what I had to do.
Notice all the rust…. On the passenger side, there was virtually none. I think the old snorkel must have let water get in between the panels.
--
October 29, 2012 at 12:45 AM Flag Quote & Reply
Outback Jack
Member
Posts: 391
More Pictures on the following Photobucket site
photobucket.com/oka169
and here
s1256.photobucket.com/albums/ii494/ntexp...%20Under%20Carriage/
--
October 29, 2012 at 4:49 AM Flag Quote & Reply
Moose2367
Member
Posts: 113
The optiair is also a mod going in mine, as the Cummins needs a lot more air than the Perkins did. Pretty sure i can get away with the 1000 model, but might go the 1100 seeing as it can be done while the cab is off.
The Perkins was sold this week too, woohoo, just the gearbox and wheels now.
October 29, 2012 at 6:22 AM Flag Quote & Reply
Outback Jack
Member
Posts: 391
Yes there is calculators onsite, cant remember where. But think the Perkins needs around 650 CFM flow for memory. So the Optiair 1100 works great. It is around that figure, maybe a little higher. However with my reducers etc, I am hoping it will balance out.
--
October 29, 2012 at 7:11 AM Flag Quote & Reply
Peter Davis & Serena Fraser
Member
Posts: 39
If I find some pictures I'm happy to post them. Off the top of my head the bosch water pump was about $100, the radiator with thermo fan was from a daihatsu at the wreckers for $120, the intercoooler was about $130. The intercooler had 3" input and output air flow with roughly dimensions 300 x 300 x 3".There are bigger intercoolers but they won't fit where I put it. I put the overflow bottle in the engine bay and a filling point. I used 1" stainless steel or alloy pipes for the water with rubber hoses for bends. I mounted the water pump under the battery directly in line with the bottom of the intercooler. I installed a couple of bleed points, an air scoop in front of the radiator and low coolant alerts for both the intercooler radiator and normal radiator. If you haven't already install a pyrometer, the temperatures obtained are quite scary esp without an intercooler. It is also the best way to judge when to turn the engine off.
--
October 29, 2012 at 8:05 AM
David and Janet Ribbans - Oka 148
Oka148 profile here.
Visit our technical and travel blogs: here.
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