Intercooler in an FSJ sporting a 4BTA

[zmjeeps]

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/

[Elliott]

That rocks!

[TexTJ209]

Nice! I'd always wondered if it could be done cleanly...and that looks very clean.

[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.

[zmjeeps]

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

[Gambler68]

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!

[men in black]

Does anybody remember who did this project?

[zmjeeps]

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

[zmjeeps]

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

[mendelo]

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 ..

[Mikel]

Very nice. I went with a Volvo intercooler. It fits very nicely, but I'm not sure how much boost it will take...

[Mikel]

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.

[zmjeeps]

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

[Mikel]

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.

[Elliott]

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.