TD5 Intercoolers

[noddy]

Howdy All

Has anyone looked at sourcing the larger TD5 intercooler from the UK, rather than using Oz based suppliers?

The quotes I have been getting from Australian suppliers for the intercooler are ranging between $1300-$1700 8O. Just looking at some of the prices being advertised in the UK, you should be able to land them here for less.

Just interested to know whether anyone has done this.

Regards

PS -- anyone interested in putting their name down let me know and we may be able to get a bulk deal.

[dhumphri]

Noddy I was actually wondering whether you could mod some of the good quality intercoolers for sale on EBAY - have seen some very good quality units with the same core size but with the inlet and outlet either high or low. These sell for $199 on Ebay:
http://cgi.ebay.com.au/GT-SPEC-DETLA-FIN-B...1QQcmdZViewItem (http://cgi.ebay.com.au/GT-SPEC-DETLA-FIN-BETTER-FLOW-INTERCOOLER-800-x300x80mm_W0QQitemZ4630840052QQcategoryZ43808QQrdZ 1QQcmdZViewItem)

[noddy]

dhumphri -- thanks. It is worth considering. :? There is a huge difference between the price of these and those for the TD5.

I have heard of some people using ones from WRXs etc.

I cannot understand why they are so expensive.

[discowhite]

for the few extra pipes required ide try the ebay ones first.
just make sure its a bar and plate type.

there are so many rice burner coolers on ebay, when i go to
do mine im shopping there. any one that can weld alloy could
mod the tanks to suit.


phil

[rick130]

I've never been impressed with the UK ones I've seen in the mags or on the 'net, to my mind the tanks look atrocious for flow.

Go here http://www.are.com.au and have a read on how this company designs their intercoolers and the pro's and con's between the different types of cores.

[51jay]

That is a very large intercooler,meant to be mounted in front of the radiator, may be more trouble than you want to go to. Glen at Brothers Offroad has just completed installing 600x300x75 in my Rangy. It was more difficult than we first thought. However I'm very pleased with the result. https://www.aulro.com/afvb/ When his site goes back up there may be some pics on it.

[51jay]

I had a custom ARE fmic in my Skyline, very good product....but a hell of a lot more than $199

[George130]

Originally posted by 51jay
That is a very large intercooler,meant to be mounted in front of the radiator, may be more trouble than you want to go to. Glen at Brothers Offroad has just completed installing 600x300x75 in my Rangy. It was more difficult than we first thought. However I'm very pleased with the result. https://www.aulro.com/afvb/ When his site goes back up there may be some pics on it.

Arn't all the TD5 intercoolers mounted in fron t of the radiator? Mine seems huge to me.

[tombraider]

Ok...

Intercoolers arent intercoolers! Just like Oils aint Oils!

Theres Bar and Plate, Tube and Fin etc.... And different profiles internally for the air charge.

Then theres flow characteristics both internally and for the cooling airflow.

These differ greatly from cooler to cooler.

Then theres tank size and design, get this wrong and you'll get increased lag, turbulence and flow issues... Bigger isnt alway the better here.

TD5s mount using intricate tabs, pegs etc... to curve around the existing radiator and condensor. Its not as easy as you may think and fabrication takes the longest time.

There is no such thing as a good EBAY intercooler, they just dont happen!

Now, having said that there are 2 core manufacturers in Oz, eg.. that extrude the cores. Adrad in Adelaide is one. They make a finned core that increases surface contact for the inlet charge and improves cooling effiency.

I use these cores....

They cost me (in bulk) around $700.00 per core

I then laser cut each component for the tanks, roll the tubes for inlet and outlet and then we play "tig the jigsaw" :wink:

We then weld and drill the mounting tabs for each cooler, flush and pressure test them and then polish them up ready for sale.

When all is said on done, you get a professionally made, bolt in, intercooler that performs correctly for the vehicle. Is efficient (over 60% better) and fits where it should.

So just how good do you think a $300 ebay special is, complete if the cores are so expensive? We're talking cores designed for our conditions made here, not tiny thin stuff that cracks or fatigues in an offroad vehicle.

Do you really want to butcher your vehicle to fit a cheapo? Or do you want the right stuff? I know some are pricey compared to others but I can tell you now. Mine work... Never had a complaint, return or issue....

And to be personally mentioned in SLunnies 4wdmonthly article must say I'm doing something right https://www.aulro.com/afvb/

Cheers
Mike

[hiline]

tombraider what would be the best price you could do them for the site ???


i know i'm after one ASAP https://www.aulro.com/afvb/ https://www.aulro.com/afvb/ https://www.aulro.com/afvb/

[MickG]

Originally posted by hiline
tombraider what would be the best price you could do them for the site ???

What he said

[rick130]

Excellent reply Mike, much better than my follow the link one. I had no idea that's what you did. 8)

Now for a question, in your experience, how close can you get to 100% efficient with an air-air intercooler, or what is a reasonable temperature difference to aim for between ambient and charge air without introducing too much lag ?
Also, do you think the 'for every 10*F drop in charge air temp=1% power/torque gain' is a valid assumption ?

[dhumphri]

So how much do your units sell for Tombraider??

[crump]

Originally posted by dhumphri
So how much do your units sell for Tombraider??


What he said, and what sort of power gain can I expect on an already chipped TD5??? :?: :?:

[noddy]

Mike -- thanks for the detailed response.

Now joining the queue.....how much??? https://www.aulro.com/afvb/ https://www.aulro.com/afvb/ https://www.aulro.com/afvb/

What torque increases are you claiming (with no remapping or increasing boost) over the standard LR cooler and the other types on the market?

All things being equal....do you believe the stresses on a TD5 fitted with both a remapped ECU and larger intercooler are less than an engine fitted with just a remapped ECU?

Thanks.

[Wortho]

What about intercoolers for 1995 300tdi discovery, do they have a good effect on the reliabilty of the engines by lowering the intake temps or is it all about performance. I'd love a bit more go but not at the expense of reliabilty as it performs well offroad standard. In other posts there were tips on tweaking the fuel delivery, but that it resulted in increasing the EGT, would a larger intercooler alleviate these issues and retain engine reliabilty?.

[tombraider]

Intercoolers arent a magic science.

The choice of a decent core is the first major step to decent performance. The second is choosing the right sized core.

Too small and theres no benefit and/or flow restriction (although the factory units are horrid!) Too big and the extra volume induces lag as the turbo has to pressurise the cooelr before flow begins to affect the engine itself.

Next comes tank design, whilst not overly critical there are some factors to take into account. Angles, size, position and strength (especially if in the case of the LR products the IC is held via the tanks to its mounts)

Benefits of upgraded intercoolers

A <span style="color:blue">correctly</span> sized intercooler will provide the following:

- Increased flow
- Increased cooling performance
- A reduction in EGTs

These are based on the following:

Increased tube flow allows more air for a desired pressure. If your turbo boosts to 19psi (like mine) then you can flow more air at 19psi through the cooler. Obviously intake and outlet do restrict this to a limit.

Increased cooling - This is where the benefits are. The larger, more efficient cores give a greater reduction in heat as the air charge passes through the core.

Cooler, denser air has several benefits. In a standard engine the reduced charge temperature and denser air provides a cooler engine, with more oxygen to burn the burn is also cleaner. Extending the life of the engine is a foreseeable benefit of this upgrade.

It will make the vehicle perform like it does on a cooler day more often.
Whilst there is an increase in performance and torque its not that great, however engine life should be improved by the reduction in heat and more efficient burn.

In a modified engine the intercooler upgrades have much more noticeable benefits. Cooler/denser air allows for an increase in fueling, allowing more power whilst keeping EGTs under control. This is the reason that the vehicles performance noticable increases with the IC fitted. An increase in torque is definately noticed with the ECU and IC upgrades.

In earlier models an IC upgrade, along with Injector pump modifications provides a delightful enhancement to the vehicle.

In response to 200 and 300tdi vehicles I have not manufactured an IC to suit these vehicles at this time.

I can however look into this in the very near future.

As for price........... https://www.aulro.com/afvb/

I currently have a limited stock here.... (business is small and I rely on normal work to fund the venture as my minimum order for IC cores runs to over $7k per run)

But can offer the following specials:

I have:

(2) TD5 Discovery Intercoolers - $1000.00 + shipping (inc GST)
(2) TD5 Defender Intercoolers - $1000.00 + shipping (inc GST)

First in best dressed, next batch will be made upon receipt of enough orders (mixed - Defender/Discovery)

<span style="color:darkred">This is a group special price only and only for this remaining quantity, due to increases in core costs due this month the next batch will likely increase in price - DO NOT DISCLOSE THIS PRICE OUTSIDE THIS LIST</span>

Cheers
Mike

[hiline]

how many do you need for this price ???

put me down for 1 https://www.aulro.com/afvb/ https://www.aulro.com/afvb/

[Belly]

i'm up, been thinking about this for awhile, chip been done but
more improvement is always good!
i'm in w.a. is fitting straight forward??
p.m. me
cheers Jeff

[WADE]

How much ?

[WADE]

Should have paged over Sorry

[roly]

has anyone had good results from flushing intercoolers? My td5 d2 has done 180k now and hasnt been touched.[intercooler] I seem to remember a thread about this procedure , cant seem to find it. roly

[George130]

Sorry flushed mine couple of days before the head let go so I don't realy know. It should help performance and economy.

[Graeme]

I swapped the I/C in my D2 for one of Tombraider's at 90k and it was absolutely clean.

[discowhite]

one of Tombraider's at 90k and it was absolutely clean


bloody hope so! other wise you got stiffed mate:D