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  #21  
Old 08-17-2009, 12:11 PM
budojeepr budojeepr is offline
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I don't have room for an intercooler in front of (or behind) the radiator, since I moved my rad forward to clear the GM 6.5. I like that angled one in front of the axle though. Any thoughts on its effectiveness? I assume the airflow would be much less...
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  #22  
Old 08-17-2009, 12:38 PM
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Quote:
Originally Posted by budojeepr
I don't have room for an intercooler in front of (or behind) the radiator, since I moved my rad forward to clear the GM 6.5. I like that angled one in front of the axle though. Any thoughts on its effectiveness? I assume the airflow would be much less...

Got any pics of what you did? How far forward did you have to move the radiator? I've got room for the 3" thick intercooler, the A/C condensor, and an alum rad and none of it sticks out past the stock radiator mounts. I was actually surprised how much room was between the grill and the radiator mount.
If your are using a full width grille (razor or later) you can cut out some of the sheetmetal on the front valance and move the intercooler even further forward than I have it. I was just trying to do it wthout cutting the front valance.

Zack
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  #23  
Old 09-08-2009, 11:38 AM
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The reason for the two intercoolers is, intercooler flow restiction. A good or effective intercooler will cause a pressure drop. Pressure drop requires more pressure at the compressor and causes more heat, do you see a repeat of events? The correct answer is to provide enough surface area for the compressed air to flow through with a allowable pressure drop. I calculated that my 401 needed 72 sq. in. of intercooler flow surface area to allow < 2lb. pressure drop @ 6K rpm. Been allmost three years and I feel its setup correctly. Hankrod
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  #24  
Old 09-08-2009, 12:13 PM
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Quote:
Originally Posted by Hankrod
The reason for the two intercoolers is, intercooler flow restiction. A good or effective intercooler will cause a pressure drop. Pressure drop requires more pressure at the compressor and causes more heat, do you see a repeat of events? The correct answer is to provide enough surface area for the compressed air to flow through with a allowable pressure drop. I calculated that my 401 needed 72 sq. in. of intercooler flow surface area to allow < 2lb. pressure drop @ 6K rpm. Been allmost three years and I feel its setup correctly. Hankrod

Like I stated before, I wasn't throwing rocks are your design or setup, just didn't understand the thinking behind the 2 intercoolers. Just out of curiousity, what formulas did you use to get the 72 sq in at 6k rpm? Is it base soley on air flow to the engine or ??? Thanks,

Zack
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  #25  
Old 09-08-2009, 12:43 PM
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Zack, no problem and I know that I'm a bit short on my replies. The formula I used was from Corky Bell's turbocharging book. I would restate it now, but I loaned it to someone...... and now its gone. I recall it to be a basic formula based on the internal fin count of the intercooler tubes and there flow rate. Hankrod
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  #26  
Old 09-08-2009, 01:39 PM
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I was playing around with these:


For your 401 assuming 85% VE, 6000 RPM CFM= 591.75 CFM
For the 4BT (3.9L) 238CID, 90% VE, 3000 RPM CFM= 185.94 CFM

So we know how much air it needs, but I'm not having much luck finding the formulas for temp drop vs core size or pressure drop vs core size of an intercooler. I know PV=nRT, so I know the two are related, just trying to double check what I've done. I've been searching around the net without much luck. (Any one else can chime in here too).

Zack
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Last edited by zmjeeps : 02-01-2010 at 04:53 PM.
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  #27  
Old 09-08-2009, 02:03 PM
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Zack, if you don't already have it, that book Hank mentioned is the turbo charging & intercooling Bible. I got mine for about $10 on ebay a while back. If you don't have one and don't want to buy, I can dig mine out and find the formula for the intercooler if that helps.
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  #28  
Old 09-08-2009, 02:19 PM
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Thanks man, I'm trying to make this thread a good resource for anyone looking to do an intercooler on an FSJ, for whatever turbo motor they would be using, so if you could post the info in this thread, that would be great. Thanks,

Zack
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  #29  
Old 09-14-2009, 03:38 PM
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Hi Zack, I have the answer from ' Maximum Boost' by Corky Bell. Basically for every 500 cfm of air flow you will need 25 sq. in. of intercooler core flow area. Now at 14.7 psi of boost a engine can double its displacement flow. So if my 407 can flow 1400 cfm @ 14.7 psi it will need 70.65 Sq. in. of flow area. Many more veriables involved but thats about it. Hankrod
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  #30  
Old 09-14-2009, 07:16 PM
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I was going to use an intercooler out of a Dodge Sprinter van:



It fit in between the outer facia and the inner sheetmetal. It is rather thin, maybe an inch thick, but spans the entire opening. The 90* turns are part of the intercooler itself. It has to be mounted low to clear the hood latch.
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  #31  
Old 09-15-2009, 07:30 AM
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Correction. The core is 2" thick, 25" wide, 10" high. There is just enough room to mount the AC condenser in front of it. And if you set the condenser at the same angle as the front sheetmetal, you could squeeze an oil cooler in there too.
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  #32  
Old 09-15-2009, 09:52 AM
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just a little small but it will work just fine. Nice fit! Hankrod
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  #33  
Old 09-15-2009, 03:55 PM
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Definitely not the solution if one is looking to hop up the engine a good amount. The Isuzu didn't have an intercooler from the factory, so I figured this would be a step in the right direction
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  #34  
Old 09-16-2009, 10:39 AM
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Quote:
Originally Posted by Hankrod
Hi Zack, I have the answer from ' Maximum Boost' by Corky Bell. Basically for every 500 cfm of air flow you will need 25 sq. in. of intercooler core flow area. Now at 14.7 psi of boost a engine can double its displacement flow. So if my 407 can flow 1400 cfm @ 14.7 psi it will need 70.65 Sq. in. of flow area. Many more veriables involved but thats about it. Hankrod

Ok, I understand what you are saying here, but where did you get the 1400 CFM #? The calc I listed above for CFM has your engine coming out with a less (600 CFM) unless I did something wrong??? I didn't take boost into account.
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Last edited by zmjeeps : 02-01-2010 at 04:55 PM.
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  #35  
Old 09-16-2009, 10:41 AM
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Quote:
Originally Posted by JeepinPete
I was going to use an intercooler out of a Dodge Sprinter van:

It fit in between the outer facia and the inner sheetmetal. It is rather thin, maybe an inch thick, but spans the entire opening. The 90* turns are part of the intercooler itself. It has to be mounted low to clear the hood latch.

Pete,
I like the ends on that intercooler. Only prob I see is squeezing the outlet between the inner fender and the rad support. That is why I did mine both up high, I didn't want to have to mess with the inner fender. Good find on the sprinter van intercooler

Zack
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  #36  
Old 09-16-2009, 11:31 AM
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It is definitely tight to the inner fender. I think I can get away with just trimming the flange of the fender. If the hook for the hood was removed, then it could be mounted quite a bit higher and completely avoid the fenders.
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  #37  
Old 10-01-2009, 06:19 PM
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More pics from Hankrod...

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  #38  
Old 10-01-2009, 06:22 PM
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  #39  
Old 10-01-2009, 06:25 PM
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  #40  
Old 10-10-2009, 09:56 AM
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Thanks for posting up the pics Elliott. Hankrod
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