£115 for performance intercooler, finally finished

This site contains affiliate links for which LandyZone may be compensated if you make a purchase.

discoverysport

New Member
Posts
72
Location
kidderminster
well I have finnaly fitted my £90 universal intercooler of ebay and all I needed was 2 3" 90 degree reducer bends that cost £12 each, one reduces to 51mm and the other to 63mm. I have used existing pipework as joiners, cutting 3" off the metal tube after the turbo to then join into the reducers and I got a piece of stainless 2.5" tube for free from local metal workers as it was just an off cut for the inlet side. the intercooler is 300x600x76 wich is bloody tight but does fit infront of the rad, the rad has moved back a bit but I feel its still a safe distance from the fan and the pipes hold it away anyway. I have had to modify the air box to allow for the extra width of intercooler and pipework but the battery side does fit as it is, in the groove already in the rad. As for the performance of the intercooler it may be a little bit to big as its created more lag but there is a definite increase in power once the pressure is up, I have adjusted actuator to increase boost and its now holding a steady 21psi and is producing far more power.
 
Any chance of a few photos? Particularly showing where and how you had to modify stuff. A photo of the intercooler itself would be nice too. Also, how long did the work take you?

I just lashed out about £350 for a Serck from Paddock. The best deal around at the moment for a dedicated Disco 2 intercooler by around £200.

If you can show others how to save another £250 on top of that you are going to be one popular guy!
 
Any chance of a few photos? Particularly showing where and how you had to modify stuff. A photo of the intercooler itself would be nice too. Also, how long did the work take you?

I just lashed out about £350 for a Serck from Paddock. The best deal around at the moment for a dedicated Disco 2 intercooler by around £200.

If you can show others how to save another £250 on top of that you are going to be one popular guy!

hi, I would say it took me 2 hours in total to do it, that includes a lot of head scratching and trying to work out how best to do it, I will go and take some photos in a minute. the whole point of my tuning has been to try and do everything as cheap as possible and hopefully get the same outcome as the most expensive tuners, I have spent £40 on a stage 2 remap and only £28 on a straight through exhaust making it myself, the only thing I am struggling with is the boost box as this is a bit to advanced for me to create.
 
some pics.
ok so...
first pic shows inlet side with egr blank then original pipe cut down to fit 2.5" pipe then into 90 degree elbow reducer.
second pic is the metal pipe on turbo side showing the cut down just before the actuator pipe comes out and then the original pipe refitted but turned a quarter turn
third pic is just showing how it sits, little high and slightly off centre
fourth pic is inlet side again showing the elbow going past the radiator
fifth pic shows how the turbo side goes under the air box
next is just the clearance of the fan
last the airbox, now I don't go off road so this will be ok for me as it is as it still holds the filter and should not get wet however I think a snorkel would be the best answer if u are likely to get water in here
 

Attachments

  • 10572174_533717036756868_2112676061_n.jpg
    10572174_533717036756868_2112676061_n.jpg
    6.7 KB · Views: 182
  • 10581147_533715750090330_982592038_n.jpg
    10581147_533715750090330_982592038_n.jpg
    7.5 KB · Views: 174
  • 10585157_533715766756995_551602723_n.jpg
    10585157_533715766756995_551602723_n.jpg
    7.9 KB · Views: 181
  • 10589694_533717023423536_1638068802_n.jpg
    10589694_533717023423536_1638068802_n.jpg
    6.7 KB · Views: 172
  • 10592275_533715670090338_794931086_n.jpg
    10592275_533715670090338_794931086_n.jpg
    7.6 KB · Views: 173
  • 10592548_533715706757001_540133005_n.jpg
    10592548_533715706757001_540133005_n.jpg
    5.2 KB · Views: 151
  • 10595780_533715576757014_154909237_n.jpg
    10595780_533715576757014_154909237_n.jpg
    8 KB · Views: 151
Last edited:
I had the same problem after putting a bit of rubber grease on a hose to get it to slide on all the way. A bit too much grease!

Pictures are a bit on the small side, but well done with the installation. The only bit that makes me nervous is that gap between the radiator and fan - it does seem VERY close. I would be concerned about the consequences of an engine mount wearing. If it's as close as it looks, I'd be looking at trying to find a way to increase the gap.
 
I had the same problem after putting a bit of rubber grease on a hose to get it to slide on all the way. A bit too much grease!

Pictures are a bit on the small side, but well done with the installation. The only bit that makes me nervous is that gap between the radiator and fan - it does seem VERY close. I would be concerned about the consequences of an engine mount wearing. If it's as close as it looks, I'd be looking at trying to find a way to increase the gap.

yeah the pictures are very small, I don't know how to get them on here properly lol its about 15mm away and yeah I am a little worried. if I can get the intercooler about 2 inches lower it will go under the front cross member but the pipe has to go through the gap already in the radiator and that is too high, only thing I can think of is try and move the radiator across a bit to allow the pipe to drop down. my other future idea is to mount it right at the front just behind the grill but this means cutting holes for the pipes to go through although it should allow for better cooling. problem is its my only car so cant have it off the road for too long at a time
 
I fully understand as I share your position in having only 1 car.

15mm does sound a bit close, but not so bad as the pictures suggest. I personally would feel safer at around 30mm or more.

Mind you, if you did have misfortune with the radiator and had to get a new one, you'd still have saved a fair bit of cash.
 
I fully understand as I share your position in having only 1 car.

15mm does sound a bit close, but not so bad as the pictures suggest. I personally would feel safer at around 30mm or more.

Mind you, if you did have misfortune with the radiator and had to get a new one, you'd still have saved a fair bit of cash.

well yeah that's true, I will try and get it moved away a bit more this weekend if I get a chance,
https://www.youtube.com/watch?v=b0qsN18pseU
have put pics on here I think you can see them a bit better, I think really I should have got a slightly smaller intercooler. do you know if the £110 boost box to stop limp mode that is on ebay is anygood?
 
My advice from what I have read on other threads would be to steer clear of it and save your cash for a re-map that includes a boost box - something like the Dynachip stage 3.

This is the route I will be taking after I have sorted my own overboosting issues and gone though every other aspect of the engine with a fine toothcomb to make sure all is workin as it should.

That way at least you will have the benefit of some good advice from the installer and perhaps a bit of come back if it all goes bang.

Read a few of the threads about turbo boost pressure and take note of what Sierrafery has to say on the subject.
 
Back
Top