Thread: 4BD1T MSA5G Range Rover Classic Outcast Adaptor

Think I've got it sorted now.

Outcast suggested I talk to National Truck Spares. Did so, and have ordered a new Isuzu slave cylinder, spring, and release bearing. Will post some photos/info once parts arrive next week.

On the subject of Outcast, said they have not had any other interest in their adaptor kits, and appreciate price is an issue for such small runs, so unless there is a sudden spike of interest they will not be making any more casings, very time consuming to make. The shafts will still be available, being relatively straight forward. They also had initial concerns about only notching one side, so put it in a lathe at high speed and all seemed OK - if I do a balancing notch I will need to use carbide grinder or such, due to the hardness.

Vern, thanks for the photos. Don't mean to create any alarm (don't want you breaking any other windows ), but, the hemispheric lump on the shaft - has it punched through the lever?

Originally Posted by workingonit

Vern, thanks for the photos. Don't mean to create any alarm (don't want you breaking any other windows ), but, the hemispheric lump on the shaft - has it punched through the lever?

I haven't had any issues with the spherical part of the push rod (think mine is bigger than Vern's) punching through the lever. But I did have problems with the lever wearing out on the pivot ball further inside the case.
I had to reweld and reinforce my original clutch fork for this reason and will check my current one next time it's out.

The clutch pedal feel was much better with a reinforced fork. Even not worn out and cracked these forks must flex a fair bit.

There's a Subaru WRX intercooler nearby on gumtree for $50 (no piping) and sure I could get the price down - also has the rear sway bar of a Disco that might be adaptable to the front of the RRC as a quick release.

Are these worth considering as an intercooler for the 4bd1t? Looks a bit bigger than the cooler for the TDi300, maybe. The Subaru engines listed are 2.2 - 2.5 litres, but I assume much higher revving with significant air supply requirements that might meet the lower revving Isuzu. Vern had something like this in one of his pics.

Full Aluminum Turbo Intercooler Bolt on Piping 95 01 Subaru Impreza GC8 GF EJ | eBay

Mine is an rx7 inter cooler, about 75mm thick, core would be 300x300 at a guess, could be bigger.

Thanks Damien, maybe I should measure it up and bargain it down

Originally Posted by workingonit

There's a Subaru WRX intercooler nearby on gumtree for $50 (no piping) and sure I could get the price down - also has the rear sway bar of a Disco that might be adaptable to the front of the RRC as a quick release.

Are these worth considering as an intercooler for the 4bd1t? Looks a bit bigger than the cooler for the TDi300, maybe. The Subaru engines listed are 2.2 - 2.5 litres, but I assume much higher revving with significant air supply requirements that might meet the lower revving Isuzu. Vern had something like this in one of his pics.

Full Aluminum Turbo Intercooler Bolt on Piping 95 01 Subaru Impreza GC8 GF EJ | eBay

Did you see this post: http://www.aulro.com/afvb/isuzu-land...ml#post2074226

The intercoolers shown there are catalogue items I found that looked like they might fit:


The front one (CXracing IC0047) is a 12x18x3.5" core and I think the biggest you can fit in the front of a classic without major body surgery: cxracing.com: Turbo Intercooler Size: 24"x12"x3.5", 3.5" Core, 2.5" Inlet & Outlet, Front Mount or V-Mount

The rearward facing outlets I was planning to run between the bottom of the radiator and above the front cross-member. The same core size is available everywhere with side entry like the link you've provided. But you have to cut a fair bit of metal from the body to get the pipes to and from it.

I then decided my 29 year old radiator is pretty much done and to go for replacement of the stock radiator and AC condensor with a redesigned condensor/intercooler/radiator setup. I'm about halfway through designing it now.

Using these parts:
Intercooler hanging on the front bumper for scale:


Total thickness gain towards the front of the engine is about 25mm. But this is a major task

Just wondered if I should grab the wrx for sale or is a waste of time.

I was contemplating mounting the intercooler somewhere else in the engine bay with an electric fan - I think that is how Damien has his if I remember his photo correctly - maybe even in the hood with a cut out and raised cover. I think though that Damien is a master of packaging more into a given space than the laws of physics would dictate is possible. A broken rear window only gives him opportunity for expansion ie rear balcony. Fixed yet?

Damien mentioned his was 300x300x75 so I ducked out in the dark to measure the 300 Tdi, which seems slightly smaller at approx 400x200x70'ish. Given the 4bd1t is not quite double the volume of the Tdi does that mean Damiens could be under rated? Or is it a case that most intercoolers are run well below their full capacity?

Anyone just used a 300 tdi radiator and intercooler with the 4bd1t?

How do you match air demand with supply? As a rough rule of thumb would you first determine air consumption volume at near engine peak revs (maybe swept volume by rpm?) and compare intercooler manufacturers claim of throughput at a range of psi ie 10. 15, 20, 25 etc).

I remember your thread, quickly read as I was not anywhere near that stage yet. Seem like some significant grill remodeling would be required. As you indicate, there is also the question of a shroud. Have you gone much past the above photo?

If I were really really serious about this project, after looking at an army perentie yesterday, I'd widen the RRC chassis by 300mm, as it seemed based on gap between starter and chassis.