Intercoolers

Are there any State-side folks that make intercoolers that you could recommend? I was considering Allisport, but I have to go custom and on top of that freight is a bear.

Thanks!

I contacted a company here in tge States that makes intercoolers,
You send them your old unit they reuse the tanks and weld in a new core. Thus all done on a jig. Was told two weeks return. Plus the core was only the allysport up-rated core size.

So the price was, this is two years ago. 400 dollars plus shipping both ways.

In the end I went with a large allysport unit.

I'll probably just contact Allisport. I need to figure out an intercooler for a new engine--one isnt offered yet for it so I didn't know if there was a company that could help fabricate that. I'll probably start with them as I already know them.

MountainD said:

I'll probably just contact Allisport. I need to figure out an intercooler for a new engine--one isnt offered yet for it so I didn't know if there was a company that could help fabricate that. I'll probably start with them as I already know them.

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I have a bunch of fabricators on Long Island that could do this for you if you want to deal with someone out of state. They just don't have a defender to test on so you would need to supply the dimensions. They build custom intercoolers for race cars all the time. No need to deal with the UK on this.

Call 631-243-6333 ask for Chris Egbert or Ed, tell them Adam with the Defender sent you.

I imagine there are a bunch of shops in Colorado that could handle this as well

Figure out what size core you need, and style (left to right, in out same side, top bottom yadda yadda)
Fabricate end tanks
Weld on mounting brackets


Really cheap route.... Find a ebay intercooler that will work and cut it up and make it fit.

There is a shop in Boulder, they pressure tested mine a while ago. Apikol is the shop, they are behind Modern Specialists on Valmont.

Allisports US agent is Randy Kremer in NJ.

Thanks everyone!

Uncle Douglas said:

Allisports US agent is Randy Kremer in NJ.

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We are the other US dealer for Allisport...

Andrew is running 4-6 weeks on builds at the moment, some items on the shelf though.

Get a hold of Matt at Road Side Werx in Lakewood. He has pretty well developed sources both here and in the UK. I did an up sized inter cooler in my D1, in the end I just got one from Allisport. The build them all the time took 21 days, shipping was about $40 for the inter cooler, and a custom PS res and some other stuff. Matt (303) 507-8876

How are intercoolers sized? This will be my first diesel so I have never had an intercooler. How is the size determined? I hear once you go too large you start to negatively impact your system--that there is a sweet spot...

The inter cooler isn't quite as important as the intake piping and exhaust. You have to be able to supply sufficient air volume for the turbo, compress that air, cool it, stuff it into the cylinders, then get rid of it. Factory inter coolers on Rovers are adequate, for a sea level application, in northern Europe and not at sustained highway speeds. Short answer is this, in Denver you probably need about 20% more inter cooler than stock due to density altitude on the cooling side. With that I would run a straight through 2 1/2" exhaust, 3" if it will fit. And an intake side with as little resistance loss as possible. That should allow you to use more fuel and keep your EGT's low enough to not cook things, say EGT's under 900 or so.