L300 intercooler scoop- success!

[Growlerbearnz]

The new temperature gauges I've installed have let me tune the transmission cooler and fan, now it's time to look at how the intercooler is doing.

Turns out that while my turbo outlet temperatures are the expected 30-140C, inlet manifold temperatures are ranging from 25-90C with the intercooler fan disabled*. The idea of the fan was that it helps in slow traffic or when stopped, but it looks like it's doing all the work, even when driving at 100kph. Time to revise the air intake.

Here's the current inlet: discreet with the mesh panels, but apparently useless-

FInished.JPG (334.12 KiB) Viewed 8134 times

So. New scoop designed with CAD** to make sure it won't look too silly:

CAD.JPG (55.53 KiB) Viewed 8134 times

Make a template from ply:

template.JPG (48.22 KiB) Viewed 8134 times

Make sure the leading edge fits:

fits.JPG (46.6 KiB) Viewed 8134 times

Modify existing deflector, merge with new scoop edge:

scoop.JPG (261.59 KiB) Viewed 8134 times

Make a bunch of internal deflector panels to seal the intercooler to the scoop, so air won't just bypass the intercooler:

deflectors.JPG (264.1 KiB) Viewed 8134 times

Next step is to paint them, fit some foam sealing strips to make it airtight (and stop the rattles), and see how it performs.

*With the fan running inlet temperature never goes above 50C, which is acceptable.
** Cardboard Aided Design

[thelazygreenfox]

Love your **CAD. Love cardboard.

In Canada it's CA nadian D ollars. LOL

Keep up the good work
MD

[Growlerbearnz]

Righto. Painted and installed, and looking more subtle in black:

MoreAngle.JPG (35.56 KiB) Viewed 8125 times

I found a little more space above and raised the front mount, giving the intercooler a better angle of attack.

deflectorsin.JPG (40.63 KiB) Viewed 8125 times

The actual scoop/deflector needs a bit of tidying up- some filler to smooth out some of the dents and distortion from welding- but I'll wait and see if it works first UPDATE: 2 years later and I still haven't got around to fixing it. It's also remarkably difficult to photograph a matte black thing underneath a car.

Black.JPG (35.73 KiB) Viewed 8125 times

Installed.JPG (37.28 KiB) Viewed 8125 times

[Morgonzo]

Nice work GB! Looks mean installed.

[Growlerbearnz]

It's (disappointingly?) subtle IRL. It mostly disappears into the black hodgepodge of radiators and ducts that is a Delica's underside. Still, if it works I'll be happy.

[Growlerbearnz]

Woohoo! It works!

Cooler withScoop.JPG (50.35 KiB) Viewed 8087 times

Intake manifold temperature never rose above 35C on a 30 minute motorway drive, even after 4 minutes of pushing it uphill at 14psi, 105kph. The intercooler fan never came on either- normally it would turn on after 10 minutes of motorway driving.

I declare a success!

[Morgonzo]

Hey GB, those digital gauges look real sharp! I'm usually a fan of the analogue style but this makes me re-think my position. I really like that each component/gauge is a different color, so when you glance quickly, you can still easily pick out the one you want to monitor.

[Growlerbearnz]

I really like that each component/gauge is a different color, so when you glance quickly, you can still easily pick out the one you want to monitor.

That was my thinking too. It's a bit garish, but you can glance at it and get the information you want.

I think analogue gauges are good for critical things- if they're in front of you, you get used to where the needles normally point and notice if one is in the wrong position. I went digital for these gauges as they're measuring things that aren't all that critical (and the gauges were cheap from Aliexpress ). Once I'm happy that all my temperatures are well controlled I imagine the display will be turned off most of the time.

[Killbert]

Growler,

Thanks as always for such a great write up! Also, the gauge setup is tops!

K