intercooling a hot air

[91rangerturbo]

Originally Posted by garrett

A couple of months ago I posted a thread about how I was going to attempt to use a 87 stock GN intercooler on my 84 T-type. Now I don't want to get into a arguement with anyone about why I'm posting this on a hot air forum. I figure others with hot air cars might like to improve the performance of their TRs with an intercooler. For me, my hot air car is my daily driver and the car I tinker with. It's also my test car where I try things. I have a highly modified 87 GN that is my pride and joy. So getting back to the thread; I put on 2.5 inch aluminum intercooler pipes that I fashioned from a universal kit. The intercooler was in the stock 87 location. I re-clocked the turbo and routed the return pipe between the intake manifold and to driver's side valve cover. Once it was completed, I noticed that above 7lbs of boost, the engine would bog down and lose power. I have plenty of fuel pressure and fat o2 numbers/ no knock. I have heard that other people who tried this have had the same problem. It has something to do with the throttle body not being on the post boost side of the set-up. Also, the hot air intake manifold is, in my opinion, horrible compared to the 86-87 intake. So now I'm going to put a 87 intake/ throttle body on the engine. I'm going to re-clock the turbo downward to it's original position and reverse the air flow through the pipes and intercooler. I have found, that in order to accomplish this and keep the turbo in the stock hot air location, I will have to modify the back part of the upper plenum/doghouse to make room. I will also tap my oil pan for a oil return. I have a few minor details to work out, like which tps sensor to use, 84 or 87. I'm sure there are things that I haven't thought of. I invite anyone who would like to offer advice or has concerns to chime in on the subject. I still think that if it works like I think it will in the end, it will be much cheaper than trying to do a full 84-87 conversion with all the brackets and pulleys.

This company local to me did something like this.
Look here. http://www.jsmanufacturing.com/

Here is a direct link
http://gallery.jsmanufacturing.com/m...g2_itemId=1432

And keep us posted on your result's i am curious how your setup works out for you. and take some

[garrett]

As far as the pipes, and the intercooler, this is almost exactly how I have it planned. I think in these photos shown in the link, they modified a hotair intake to make it a open plenum set up. I am using a 87 intake because I like the the way the runners inside are designed. Also, I don't have all the welding and fabrication resources to modify a hotair intake like they did. I am re-using the stock hotair metal bracket which mounts the turbo on the passenger side of the intake. I also modified the upper plenum in the same way they did.

[garrett]

I'm trying to add more pictures. I'm no computer geek.

[garrett]

One more time

[garrett]

This is how the current set up is configured. Keep in mind I haven't put the 87 intake/throttle body on yet.

[garrett]

Ok, last picture. I don't know why I couldn't put hem all on at one time, sorry.

[Keller]

Looks pretty trick.

You can only do one pic at a time here.

[91rangerturbo]

photos look good and interesting setup. you can start a online photo album for free from a place like this http://photobucket.com and makes posting pics easier.

[garrett]

I have decided to run the oil return line from the under side of the turbo, to the oil pan. I had a local welding shop weld a# 10 fitting to the flange for the oil return hose, after I cut the ribbed alloy hose off of it. I had them weld the same type of fitting to the side of the oil pan. Tomorrow, I'm going to Aeroquip and getting a 3ft long piece of hose to connect the two fittings. I want to replace the rear main seal when I have the oil pan off, its leaking like a mother***** right now. I'm waiting for a 87 TPS sensor to come in the mail from Poston. A good friend of mine is giving me a billet turbo inlet bell to attach to my TA-33 turbo. I believe after that, I will have all the pieces. I'm going on vacation for two weeks, but sometime around the third week in Oct. I should have time to complete the project. Stay tuned

[garrett]

here's some more pictures