Intercooler

[POPEYE]

Eventually made a start on it, spent ages moveing it about on top of the engine to get a rough best position, i'm going to edit this up as i go as i'm bound to forget half of it if i leave it to the end (finished job) I'm useing the cooler Jotto kindly sent me which is from a L200 Mitsy(i think) , it's pretty big and as i'm not now doing a 2" body lift it's going to need a bl00dy big hole and scoop,
I'm fitting a tray under it to sort of act as a heat deflector and air/water channel so thats the first step, after makeing a bolt on spigot to take a 2"
hose (there was'nt one on the cooler and i could'nt be arsed going to a mitsy dealer to find the part) made it out of some 2"copper tube and brass plate,
The cooler has six blanc protrusions on the underside and i drilled and tapped these to accept six studs and nuts/spacers to bolt the tray to (some fileing to do to line it up better) then a second "L" shaped alloy plate to go on next.
seal it up and all air/water passing through the fins should be deflected to the rear,
Last two pic's are all the alloy deflector fitted

Whichever way i work this it's going to cost me a sodding fortune in silicon hoses

[dirtydog]

looks about the same size as the one I need to fit still.... let me know if you find a nice scoop

[POPEYE]

looks about the same size as the one I need to fit still.... let me know if you find a nice scoop

Think i going to have to make one, cant find anything "off the shelf" thats going to be big enough, i'm still not sure wether to make it out of fibreglass or try me panel beating skills on a great big sheet of copper plate i've got,

Dont think they make a bakeing tray that big Tim

[MattF]

Fibreglass will probably be easier. Looking good Ian. :thumbsup. Just on a tangent, that 2" copper pipe. Is that the largest diameter you can get as standard, or is there a larger bore copper pipe as well?

[POPEYE]

Fibreglass will probably be easier. Looking good Ian. :thumbsup. Just on a tangent, that 2" copper pipe. Is that the largest diameter you can get as standard, or is there a larger bore copper pipe as well?

I'm not sure Matt, this pipe came on the dennis coach chassi's and was part of the water jacket, we had to remove em to fit the diesil powered water heaters and this lenght of pipe was chucked away, i used to saw em up and bring em home for s$$$$, i wish i'd kept em all now, especially the bends, the biggest copper tube i've actually bought was 1 1/2" but i guess larger sizes are available, cost a fortune though,

[plumb bob]

Look for one of the national plumbers merchants like plumb/pipe center or PTS(plumbing trade supplies) they will keep large tube, or be able to get it to order.

note; 2" and above tube will come in 3 metre lengths and will cost upwards of £60.00 a length.

Nice work Ian, did you soft or silver solder that copper/brass flange?

[POPEYE]

Look for one of the national plumbers merchants like plumb/pipe center or PTS(plumbing trade supplies) they will keep large tube, or be able to get it to order.

note; 2" and above tube will come in 3 metre lengths and will cost upwards of £60.00 a length.

Nice work Ian, did you soft or silver solder that copper/brass flange?

Yep soft solder'd it, i added a brass ring as well to give it a bit of strenght, plus the copper tube inserts about 10mm into the cooler, bit of fileing req to get it to fit snugly, there should'nt be a lot of stress on the joint though,
I guess'd big bore tube would be expensive, the last bundel of 15mm i bought was about £23, now its £60-70
Just priced up the silicon hose and it's gonna be £87.75 plus post etc, it's worse than copper

[plumb bob]

Yep soft solder'd it, i added a brass ring as well to give it a bit of strenght, plus the copper tube inserts about 10mm into the cooler, bit of fileing req to get it to fit snugly, there should'nt be a lot of stress on the joint though,
I guess'd big bore tube would be expensive, the last bundel of 15mm i bought was about £23, now its £60-70
Just priced up the silicon hose and it's gonna be £87.75 plus post etc, it's worse than copper

I had a price on 3 mtetres of 54mm copper from PTS awhile ago and it was £80.00 +vat.

[plumb bob]

You'll have to post up the results on improved performance when it's all done, as intercooler is on my wish list, when I've fixed all the other problems.

[MattF]

You get shafted whichever alternative you go for then. That ain't cheap for either of 'em.

The copper pipe question was just another of my snorkel moments. Keep thinking of sad alternatives to standard steel/alloy tube.

[Chillitt]

Ian, I might be able to lay my hands on some 'offcuts' of brass 2" tube. let me know if I can help.

[plumb bob]

I wouldn't use copper tube for anything other than water, as when it oxidizes you get that nice green colour, which can become a powdery deposit that is poisonous, and may also flake off and ente your engine. Thats a bad thing.

[POPEYE]

Thought you were thinking of 3" copper exhaust Matt
I take your point about oxidisation Bob, i was thinking of useing this copper as joiners, there wont be much of it as most will be silicon hose, just make em long enough to get two jubilee clips on each end, but i might take you up on that offer Charlie, dont need much of it, guessing about 8-10" for all the joiners, let me know about postage etc mate, if you've still got it!
The pi$$er is we used to have loads of silicon hose at the buss place i worked, i dont fancy going back there cap in hand and asking for some after telling em to stick their job up their arse

[Chillitt]

I'll bung a foot of it in the post, Ian. (As long as I can find it!!)

[POPEYE]

I'll bung a foot of it in the post, Ian. (As long as I can find it!!)

Thanks Charlie, appreceiate that, BTW if you fancy fitting an intercooler on your truck i got one from a 3.1 td Trooper your welcome to, it's a bit smaller than the one i'm fitting and may be easier to fit but i fancy'd the big one, let me know if you want it