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  #1  
Old 08-15-2009, 09:23 AM
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Intercooler in an FSJ sporting a 4BTA

I started a seperate thread with this because this intercooler setup can work with any FSJ as the front end sheetmetal never changed.
The 4bta that is going in Project Humpty needs an intercooler. I pested Dusty and some others about how to do it and got some pics. Depending on what grill you use, you can hide a lot of intercooler behind the bigger FSJ grills. I put a couple of restraints on this design. While this project is going to get a razor grill, I wanted to be able to fit the intercooler in without cutting too much sheetmetal and maybe still hide it behind a Rhino grill if I do another one of these. I also wanted to keep the size of the intercooler (lxwxh) as close as I could to the intercooler that came with the 4bta in the box truck. So with all that in mind, I give you...



I got some 90 degree hose ends and that is how it will be coming through the radiator support like so:



Personally, I think this shot looks bad @$$:



Couple more pics here: http://s689.photobucket.com/albums/v...y/Intercooler/
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  #2  
Old 08-15-2009, 09:39 AM
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That rocks!
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  #3  
Old 08-15-2009, 10:22 AM
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Nice! I'd always wondered if it could be done cleanly...and that looks very clean.
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Old 08-15-2009, 10:32 AM
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Cool project Zack

I have a couple photos of a twin intercooler for a turbo 401 FSJ setup
if you want me to post them.
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  #5  
Old 08-15-2009, 10:44 AM
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Quote:
Originally Posted by men in black
Cool project Zack

I have a couple photos of a twin intercooler for a turbo 401 FSJ setup
if you want me to post them.

I remember some of those pics. Go ahead post them. Might as well keep all the reference material together...

Zack
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Old 08-15-2009, 11:33 AM
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Quote:
Originally Posted by men in black
Cool project Zack

I have a couple photos of a twin intercooler for a turbo 401 FSJ setup
if you want me to post them.

I've seen those pics. Jeep porn

Zack, with all the nos parts you have..that core support? Looks burly!
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Old 08-15-2009, 11:35 AM
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Does anybody remember who did this project?






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Razor grille, Hella H4 headlights, Piaa driving, LED spider taillights, tinted windows.
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Edelbrock intake and 2132 cam, Howell TBI, Ford Distributor Cap, TFI Ignition Coil, Desmogged
















Last edited by men in black : 08-15-2009 at 11:38 AM.
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  #8  
Old 08-15-2009, 12:33 PM
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Quote:
Originally Posted by Gambler68
Zack, with all the nos parts you have..that core support? Looks burly!

This is the mock up build. I figure I'd do it on an old one before I drill holes through the NOS rad support. This is just one I had laying around, its not the one that is going to get used...
It does make it nice sitting on the bench doing it rather than on the vehicle...

Zack
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  #9  
Old 08-15-2009, 12:35 PM
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Quote:
Originally Posted by men in black
Does anybody remember who did this project?

I remember that project and I remember thinking that I didn't like the one under the bumper. I don't know the core size of the intercoolers pictured, but I would think I almost have as much core with this one as he has with two, almost...

Zack
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  #10  
Old 08-15-2009, 02:35 PM
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Quote:
Originally Posted by zmjeeps
I remember that project and I remember thinking that I didn't like the one under the bumper. I don't know the core size of the intercoolers pictured, but I would think I almost have as much core with this one as he has with two, almost...

Zack

I agree. I always thought the point of two intercoolers was to send the air through the first one to cool and then a second to cool even further. Here it seems the air flow is simply being split, so one larger on top would have accomplished the same as the complexity of having two.

Nevertheless ..
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Old 08-15-2009, 02:41 PM
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Very nice. I went with a Volvo intercooler. It fits very nicely, but I'm not sure how much boost it will take...

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Old 08-15-2009, 02:42 PM
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Quote:
Originally Posted by zmjeeps
I remember that project and I remember thinking that I didn't like the one under the bumper. I don't know the core size of the intercoolers pictured, but I would think I almost have as much core with this one as he has with two, almost...

Zack

He also has twice the plumbing, which is not helping with air flow. I'm not sure why he didn't go with a larger intercooler (in surface area, not thickness), but impressive, nonetheless.
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Last edited by Mikel : 08-15-2009 at 03:32 PM.
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  #13  
Old 08-15-2009, 02:46 PM
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Quote:
Originally Posted by Mikel
Very nice. I went with a Volvo intercooler. It fits very nicely, but I'm not sure how much boost it will take...


Is your intercooler between the stock radiator mounts and the radiator you have just behind it? Are you using a fan? What kind? I'm still trying to work out the hose routing...

Zack
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  #14  
Old 08-15-2009, 02:57 PM
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Quote:
Originally Posted by zmjeeps
Is your intercooler between the stock radiator mounts and the radiator you have just behind it? Are you using a fan? What kind? I'm still trying to work out the hose routing...

Zack

The intercooler is where the radiator used to be. The engine is way back, partly to help with weight distribution and also to allow room for a 6BT if the need ever arises (which will not happen).

I have an electric puller fan that I haven't installed yet. It will go in front of the intercooler. I haven't installed it since it takes sooo long for the engine to overheat in traffic. I've only had to shut off the engine one time since October.
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Old 08-15-2009, 03:14 PM
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Quote:
Originally Posted by men in black
Does anybody remember who did this project?




Henry Lavrenz, "Hankrod". I have more pics and info but he checks in around here off and on, been awhile since I've seen him logged in though.
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  #16  
Old 08-15-2009, 08:41 PM
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Quote:
Originally Posted by zmjeep
I Personally, I think this shot looks bad @$$:


Heck Yeah!!!!!!!!!!!!!!
With something like that you don't even need a grill.
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I don't think an apology is needed. Most of us are pretty opinionated even when we are wrong.

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  #17  
Old 08-16-2009, 08:35 AM
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Quote:
Originally Posted by Carleysjeep
Heck Yeah!!!!!!!!!!!!!!
With something like that you don't even need a grill.

Just to keep the birds out...

Thanks for all the kind words guys. I didn't mean for Hankrod's stuff to get posted and then put down. Anyone who can do a set up like that is OK in my book. I'm sure there is a reason for the 2 intercoolers, hopefully we find out what that is.

Mikel, Couple more questions for you. You have a 'hump' hose on the turbo side of the intercooler, should there be one on the other side too? The reason I ask is, the set up I took off a 6bt only had one hump hose and it was on the engine intake side. Didn't know if one side or the other was right, or if it should be 2...

Just me in uncharted waters again...

Still turns my stomach that I have to do all the cutting on the NOS sheetmetal.

Zack
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  #18  
Old 08-16-2009, 09:36 AM
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Quote:
Originally Posted by zmjeeps

Mikel, Couple more questions for you. You have a 'hump' hose on the turbo side of the intercooler, should there be one on the other side too? The reason I ask is, the set up I took off a 6bt only had one hump hose and it was on the engine intake side. Didn't know if one side or the other was right, or if it should be 2...


I put that there to compensate for a bit of misalignment in the piping. The rubber elbows didn't give me the exact angles I needed. I may add one in the other side, to help dissipate some of the engine vibration and keeping it from stressing the intercooler too much.
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Old 08-16-2009, 10:19 AM
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Quote:
Originally Posted by Mikel
I put that there to compensate for a bit of misalignment in the piping. The rubber elbows didn't give me the exact angles I needed. I may add one in the other side, to help dissipate some of the engine vibration and keeping it from stressing the intercooler too much.

That's what I was thinking, one in either side for engine vibs. I got a piping 'kit' with a bunch of straight pieces, 90s and 180s of alum pipe and a bunch of silicon connectors so I'm going to try to pipe it all together witout having tig the alum pipe. We'll see. It also has some 90 deg and 45 deg silicon hose pieces. Here's a pic of the kit...




Zack
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  #20  
Old 08-17-2009, 11:45 AM
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I used 90 deg silicon elbows to go from the ends of the intercooler through the radiator support. Should be straight shots to the engine and the turbo after that...

Zack
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