reworked Saab intercooler to fit Isuzu 2.5

[wbski007]

Well I'm up to my old tricks again making odd things fit, I reused my Saab intercooler, If you remember I used this Saab intercooler before but I had to use alot of extra piping to hook it up because both inlet and outlet pipe both faced in the same direction, the case is made out of some kind of composit material, so I cut it with a hacksaw and turned the outlet side around 180 and then used 2 part epoxy to mate it back together, I drilled a series of 1/8" holes all around each half about 10mm apart so when I applied the epoxy it went into the holes to give a better grip, seamed to work ok as its been on the motor for about two weeks now and no cracks. I lost alot of boost pressure the first time I used the Saab intercooler probably due to all the extra piping so I removed it, now after reworking it and the the use of less piping it works great, no lost boost, I figured what the hell I ain't got nothing to loose by cutting it as it was just sitting on my shelf anyway, I'm glad I did now as the 2 part epoxy worked great, its harder than steel. I had to use some machanics wire tho to help hold the hose on the outlet side because the intake manifold doesn't have a lip, the hose kept blowing off, I know its kinda mickey moused but the wire has held it on so far, have to come up with somthing that looks a little better than wire. If I could weld alumium I could put a bead around the lip of the intake then the clamp would have something to hold on to so the hose didn't slip off. I could use epoxy like I did on the composit but I don't know how well it would work on alumium??
well anyway it works and that's what counts, I've ordered a hood scoop and I'm mounting it over the intercooler and that should just about do it.

[iananita]

How often do you change oil?

[wbski007]

it doesn't look like from the top but there's just enough room under the intercooler to take the oil cap off and get my flexable funnel in there to add the oil I just changed it the other day!

[iananita]

Good one!

Great mod!

[slightlydodgy]

That epoxy putty is good stuff I once used it to repair a crankcase on a dirt bike after my workmate put the chain through it

[steveNZ]

i with you on the 2 part epoxy that's what i used to secure fittings to oil catch

[wbski007]

added a fan to my intercooler today and what a differance it made in tempeture, I already had a temp gauge hooked up to my intercooler, just wanted to see what kind of temps it was running, before I added the fan it would run at between 140 degrees and 170 degrees, turned fan on and it droped to 120 degrees and stayed there, big differance. Also raised the back of the bonnet up a few inchs to let the hot air escape faster, its a old race car trick to help keep your motor a little cooler.

[scruff123]

were did u run the air temp sensor into? did a tap and srew it into the intercooler? cheers

[wbski007]

Yeah Scruff the Saab intercooler had a brass plug in one end, for what I have no idea, but it was the perfect size for a mechanical temp probe, I had this engine water temp gauge sitting around so I thought what the hec, water temp and air temp are the same it should work and guess what, it did, what's one more gauge to look at when you have 10 already, I was just really curious as what kind of temps the air in the intercooler were, I thought they would be higher than they actually are, but in any case the fan makes a big differance