What Intercoolers have people installed on their ZD30's

[Mckenna2208]

Had a quick search but couldn't see much on it but just curious as to what Intercoolers people have installed on there ZD30s and how hard was it? Looking into doing something like this myself have an intercooler off a ford courier sitting in my garage I'd like to use but not limiting myself to that.
Feel free to show some pics

 

[vicszd30]

Howdy,, Personally cross country units are far to heavy a unit to be mounted so far off centre to the motor and the bracket at the rear of the unit goes to a bracket on the turbo that should "at most" only hold the heat shield it was designed for.. Just say'n!
Then you have the issue of getting the unit to seal to the bonnet "a problem I AM still working on and with no help what so ever from the geniuses at cross country"!
The service is second rate at best and this is far form a "KIT" as it is "sold as"! Your dollar Your choice! And at $1600 what a rip- the kit was damaged and the complaints go on!
If I had my dollar to use again I would work with the guys at Plazman and work out a Water to Air unit!
Hard mount the w/a cooler to the inner guard and run a mix of hard pipes and silicone to get it plumbed
There is a guy on here that does a front mount -Forfront Industries I think he's called- I'd go that way before top mount "any day"! I grabbed a hi flowed Turbo off him that's 5000k's in and it's doing a great job so far!
Anywayss be warned, cheers Vic

 

[d22dave]

Howdy,, Personally cross country units are far to heavy a unit to be mounted so far off centre to the motor and the bracket at the rear of the unit goes to a bracket on the turbo that should "at most" only hold the heat shield it was designed for.. Just say'n!
Then you have the issue of getting the unit to seal to the bonnet "a problem I AM still working on and with no help what so ever from the geniuses at cross country"!
The service is second rate at best and this is far form a "KIT" as it is "sold as"! Your dollar Your choice! And at $1600 what a rip- the kit was damaged and the complaints go on!
If I had my dollar to use again I would work with the guys at Plazman and work out a Water to Air unit!
Hard mount the w/a cooler to the inner guard and run a mix of hard pipes and silicone to get it plumbed
There is a guy on here that does a front mount -Forfront Industries I think he's called- I'd go that way before top mount "any day"! I grabbed a hi flowed Turbo off him that's 5000k's in and it's doing a great job so far!
Anywayss be warned, cheers Vic

I second some of the above, I have the cross country top mount on my 04 model, the fan lasted just past the warranty period by a month, if I had my time over again I would probably go front mount.

 

[Mckenna2208]

Yeah I would definitely go with a front mount, peformance wise how much of a gain did you get from adding an intercooler?

 

[1310/71]

I installed a large front mount kit from Forefront Industries. At std boost no problems, when I upped the boost to 20psi I had issues with hoses coming loose. I've since extended one of the pipes at the front to fit into the silicon hoses better and turned down the boost to 18 (unrelated to this issue) and haven't had any issues since.

 

[04SilverSTR]

Waic all the way, i have a modded subaru cooler on mine but have seen ebay units on zd's as well.

Cheers
Bryan

 

[Mckenna2208]

Have you got some photos of how you fitted up your Subaru intercooler? And of where all the piping went?

 

[vicszd30]

I second some of the above, I have the cross country top mount on my 04 model, the fan lasted just past the warranty period by a month, if I had my time over again I would probably go front mount.

Yes mine too! Except it's easy to see why the fan shat it's self - have a look at this gem! Yup and they wont cover it under warrantee ??? This is just one of many issues with this so called "KIT" from cross country !

 

[vicszd30]

Yeah I would definitely go with a front mount, peformance wise how much of a gain did you get from adding an intercooler?

None really -other than the piece of mind I get if the turbo shat it's self the intercooler should catch it
Until I can get it to seal from bonnet to cooler it will be doing nothing and if anything will be making the temps worse as it will be heat soaking until I get it fixed- Cross ****ry you mutts!

 

[dtr19]

I have a plazmaman front mount. I think the quality is very good. I have a lot of pics of the install, I will post some. They are expensive, but the install looks factory. The instructions were average. I can provide better instructions if anyone ever installs one.

 

[dtr19]

Also you have two types of cores used in air to air intercoolers. Do your research on which is better.

 

[Mckenna2208]

I have a plazmaman front mount. I think the quality is very good. I have a lot of pics of the install, I will post some. They are expensive, but the install looks factory. The instructions were average. I can provide better instructions if anyone ever installs one.

Yeah photos would be good mate cheers

 

[dtr19]

plazmaman install

First lot of pics

Note the radiator support panel needs some panel beating to fit the top pipe through. I did it with a G-clamp and then a rubber mallet. I probably have about 100 2-3M pictures of the install.

 

[dtr19]

plazmaman install

pics no.2

 

[dtr19]

plazmaman install

pics no.3

 

[dtr19]

plazmaman install

pics no.4

The power steering cooler needs the pipes adjusted. I did this with a small gas torch to slightly heat before bending them. I inserted a solid piece of stainless steel to keep the shape before heating.

 

[dtr19]

plazmaman install

pics no.5

pic 3762 I rotated the pipe an additional 45 degrees later.

 

[dtr19]

plazmaman install

pics no.6

 

[dtr19]

plazmaman install

pics no.7

img 3605 radiator hose clamp needs to be moved to the other side to allow room for the IC pipe.

 

[dtr19]

This install was for a factory nissan bullbar.