Mods to reduce Engine Air Inlet and ATF temperatures.

[Dicko1]

I wonder if it is easier to fit nutserts to the angle brackets as I do not want to remove the bash plate to fit the wings.

I didnt have to remove the bashplates. Simply used a cordless drill with correct size bit for nutserts...naturally drilled a smaller pilot hole first. Easy enough to on a driveway or garage floor. I dare say people will make up their own variants to suit. Using a jigsaw and the cutting board just made it cheap, quick and easy. If you want to get flash go the laser cut and put a fold in the wing where it can bolt to the bashplate. I used stainless pop rivets to hold cutting board to right angle bracket.

[insect_eater]

It looks like Kieron (and the forum members) have access to an incredibly well qualified, experienced and enthusiastic R&D team. With the multiple lines of thought being addressed, it should be a great result.

Terrific stuff!

[geopaj]

I like this idea! You’ve set my engineering mind going!

It’s currently untested but I have made up a ‘proof of concept’ intercooler guard out of 0.9mm stainless (I had it at hand and it’s easier to work than 4mm steel plate!).

It is the same profile as a Bushskinz guard with slightly larger air intake holes than the OEM guard - however the holes are higher up than the OEM guard (hopefully to stop them collecting sand).

I will make some side infill pieces, do some back to back testing (comparing engine intake air temps), and report back.

Obviously, if it is a success the guard will need bracing gussets (due to the size of the air holes) and mesh covers (to stop sticks damaging the intercooler). With appropriate gussets it should be as strong as Bushskinz.

[insect_eater]

Could the side infill pieces also function as the bracing gussets?

[nj swb]

It’s currently untested but I have made up a ‘proof of concept’ intercooler guard out of 0.9mm stainless (I had it at hand and it’s easier to work than 4mm steel plate!).

It is the same profile as a Bushskinz guard with slightly larger air intake holes than the OEM guard - however the holes are higher up than the OEM guard (hopefully to stop them collecting sand).

I will make some side infill pieces, do some back to back testing (comparing engine intake air temps), and report back.

Obviously, if it is a success the guard will need bracing gussets (due to the size of the air holes) and mesh covers (to stop sticks damaging the intercooler). With appropriate gussets it should be as strong as Bushskinz.

Good job geopaj - I like what you're doing.

Let me know if I can help with your testing.

[geopaj]

Good job geopaj - I like what you're doing.
Let me know if I can help with your testing.

Thanks mate

[geopaj]

Have also made a second ‘top half’ - MK2 with vertical facing air intake holes and external gussets which hopefully will have a funnel effect. It’s made to be interchangeable with the top half of MK1.

Still all made of light sheet off cuts (aluminium this time) to confirm what works best.

None may work but I’m having fun experimenting!

[vladguan]

Thanks mate

Have also made a second ‘top half’ - MK2 with vertical facing air intake holes and external gussets which hopefully will have a funnel effect. It’s made to be interchangeable with the top half of MK1.

Still all made of light sheet of cuts (aluminium this time) to confirm what works best.

None may work but I’m having fun experimenting!

You my friend have too much time on your hand.

[NTBenny]

I don't mean to detract from the great initiative shown above but has anyone tried water injection on a Pajero to reduce intake and exhaust temps? I've used a water/meth injection system on my GT Falcon before but not on a diesel.

http://www.dieselarmy.com/engine-tech/how-it-works/how-it-works-water-methanol-injection/

Benny.

[Pajshomoneroguntero]

I was thinking of a water injection system but not into the intake as suggested by NTBenny. Rather spraying a coolant (water) in front of the intercooler probably a mist to assist the heat exchange process.

[vladguan]

I was thinking of a water injection system but not into the intake as suggested by NTBenny. Rather spraying a coolant (water) in front of the intercooler probably a mist to assist the heat exchange process.

Fancy that. Someone just suggested the exact thing on the FB page. Using the headlight washer components and activated via a switch to spray onto the intercooler.

At the moment I have been monitoring the IAT and at cruising speed, with outside temperature at 35, was getting IAT as low as 45. This increased to about 75 while idling at the lights for some time when stuck at traffic jams. Ideally, you would want the water spray during idling, however, there would be no air flow for evaporative effect to take place.

[old Jack]

By improving the airflow this is a one off mod with no further actions or consumables required, if this is not enough then a larger intercooler is required.

OJ.

[NTBenny]

I certainly like the idea of a bigger intercooler mounted up top away from the mud etc. At $1500 or so it ain't a cheap mod though.

With a water injection system I'd potentially have it only spraying when EGTs hit >500deg. This being the case you wouldn't use much water.

I've seen external water spray systems for intercoolers and they can use quite a lot of water with minimal reduction in IAT. There can also be quite a delay (10-15sec) from the initiation of the spray and seeing a change is IAT. This is probably not an issue for towing up a long hill with a Pajero but in performance car terms most throttle applications are not much more than 10-15 seconds. Probably worth investigating on a diesel 4WD though.

Benny.

[geopaj]

Ok... I did some testing this afternoon on the Northern Expressway (aka Gawler Bypass), using Munno Para Bunnings carpark as a safe place to swap guards.

From Bunnings (Curtis Rd) I drove on the Northern Expressway using cruise control at 110km/h to the Two Well Rd exit (5.6km) before crossing over and driving back using cruise control at 85km/h to Curtis Rd and Bunnings. I then repeated this with each setup and recorded the lowest intake temperature (which each time was just before existing the Expressway).

During the testing the ambient temp remained 35-36 degrees as per the dash readout.

My vehicle has an ARB bullbar with winch and is generally a heavy beast.

RESULTS:
MK1 (with a baffle between the bullbar & the front crossmember, and baffles each side of the intercooler guard like Dick1).
110km/h - 34 above ambient (EAI temp 69c)
85km/h - 20 above ambient (EAI temp 55c)

MK2 (with the above baffles)
110km/h - 31 above ambient (EAI temp 66c)
85km/h - 18 above ambient (EAI temp 53c)

Bushskinz (unmodified but with the above baffles)
110km/h - 31 above ambient (EAI temp 66c)
85km/h - 19 above ambient (EAI temp 54c)

Bushskinz (unmodified and NO baffles)
110km/h - 30 above ambient (EAI temp 65c)
85km/h - 17 above ambient (EAI temp 52c)

Not the results I was expecting! and not the same outcome that Pajero12 experienced (thought he has a genuine MM bar which provides a shit load more airflow than ARB bars).

Thoughts? Ideas? Suggestions?

Some may call it a complete waste of time but tinkering in my shed is a great destresser for me and sure best watching TV all night every night.

I wouldn’t mind doing another back to back test to compare a standard Bushskinz guard and one modified like nj_swb’s (nj, do you want to join me one evening for a run up the Expressway swapping guards on both vehicles?)

[nj swb]

Hmmm. Not the results I was hoping you'd report.

To be honest, I think the last three results are "no result" - not a significant enough difference to call one way or the other.

Did you have much gap under the intercooler? Do you think there was much air escaping under rather than through?

I'm happy to help out with some testing - with a little notice I should be able to make any night work. I also have Pajero12's original factory guard, if you want to try to work that into testing?