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MERRY CHRISTMASMERRY CHRISTMASMERRY CHRISTMAS

High Flow

Intercoolers

G guy Motors in conjunction with Cross Country 4x4 has launched in NZ an exclusive range of race-proven high-performance Intercooler kits for de-livering huge power increases while being bullet-proof reliable too.

We chose Intercooler kits manufactured by Cross Country 4x4 on top of PWR cores because, like us they have had a great deal of off-road racing ex-perience and have tested their kits against their competitors in the harshest of environments with-out a single failure.

That is why we are so confident in offering these Intercooler kits to our customers.

Be assured these Intercooler kits have been put through their paces, tested on and off-road by 4x4 enthusiasts. In fact, in this special Newsletter we go through the results of our own testing based on a Top Mounted Intercooler kit fitted to our demo-truck.

PRODUCT REVIEW

SPECIAL

The Intercooler kit quality manufactured by Cross

Country 4x4 has been recognised as industry leading

in Australia.

“We were so impressed with built quality of the kit we

tested the power increase using a dynamometer to

measure the maximum power before and after the kit

was fitted”

Page 2 Volume 1, Issue 4

Basic product review facts:

Test vehicle: 1993 Nissan 4.2 Safari GQ Fac-tory Turbo

Test scope: Intercooler; Turbo boost; Fuel pump

Test equipment: Dynamometer & Grant’s ex-perience!

In a nutshell, we use the Dyna-mometer to record the power output before and after fitting the Cross Country 4x4 Inter-cooler kit designed for the Nissan GQ Safari/Patrol.

Throughout the test Grant and his team looked at factors such as kit built quality, ease of fitting and performance in coming up with their view of the product and its value for money.

Before we get into the details from our product test, a little more about the product features and background.

The Intercooler kits come in a large range of mod-els, designed specifically to maximise the best power curve for each vehicle. Cross Country 4x4 has achieved this by putting in countless hours of R&D work so they outperform other similar cool-ers for cost effectiveness, performance and durability.

These kits come as a standalone Front Mounted Intercooler (FMIC) kit or a Top Mounted Inter-cooler (TMIC) kit with the following features:

An ultra-high quality custom-built PWR Core (PWR custom-make cores for these kits!)

Kits designed to run quality stainless pipes where they will avoid damage

Custom fabricated high flow tanks from quality 3mm sheet aluminum

Manufactured in close tolerance jigs us-ing Pulsed TIG welding

Crafted 2.5" stainless mandrel bent piping

Kits come with complex pipe work, easy to fit and with the least amount of joins

These Intercooler kits have fast grown in popular-ity and are now the leading Intercooler in the Australian 4x4 market.

First of all you need to decide if a top mount cooler (TMIC) will best suit your needs, or whether a front mount cooler (FMIC) will do the trick. Generic coolers are often promoted as ca-pable of working with all types of vehicles, but that is just not the case. Cross Country 4x4 cus-tom design and make their kits to optimise the power curve for your vehicle type and use. These kits are built on top of tailor-made PWR cores and not off the shelf units, custom cores that are extremely strong while maintaining a high flow to heat dissipation ratio. Recognised as some of the best cores in the market and proven time and time again on the race-track these give the kits a solid performance guarantee. Traps for the inexperienced exist, with many Chi-nese imported coolers found to underperform.

Designed by 4x4 enthusiasts, tested by 4x4

enthusiasts and backed 100% by 4x4 enthusiasts.

G Guy Motors can fit these kits, or they can be

supplied as a DIY kit with everything you require to fit a cooler system included, designed with

installation ease in mind.

Cross Country 4x4 Intercooler Kits – What’s the big

difference?

Page 3 4X4 Driver’s Newsletter

rounded leading edge tube design throughout the manufacturing process. These tubes have an integrated internal fin with a straight-through de-sign, which improves heat transfer for less pres-sure drop, resulting in higher flow and reduced lag time.

PWR intercoolers are individually hand manufac-tured with the following features:

Low restriction internal turbulators

Leading edge tube wall thickness for strength

Light weight

Race and street proven performance

Hi-tech “Auto CAD” design

A turbo compresses the intake charge of air to a higher atmospheric level. A byproduct of this compression of the intake charge is heat, and it has to be displaced. The best way of displacing this heat on an engine is an intercooler system. Basically, an intercooler is a heat exchanger. It exchanges thermal energy from one source to another and simply displaces heat. There are a few reasons why this heat is undesir-able, but the main issue we will look at is per-formance and reliability of your engine as well as economy. As hot air is less dense than cold air, the amount of fuel you can atomise into hot air is considerably less than it would be if the air was cold (dense). For obvious reasons the amount of fuel/air mix entering your engine has a fair bit to do with per-formance of your engine. More fuel and air equals more power. The more power you gain and the more efficiently your engine is running means the less you squeeze the throttle to do the same amount of work. This simply means increased economy. That is why you have

With a tendency to heat soak (not being able to disburse the heat evenly with ample air flow because the cooler is a t s a t u r a t i o n p o i n t ) and consisting of very fragile

fins – these cheap copies result in an expensive lesson for the few bits of flimsy alloy piping you get! Cross Country 4x4 fabricate custom high flow tanks from quality 3mm sheet aluminum. These tanks are CNC folded and pulse Tig welded - in-side and out - to ensure durability and high flow. Manufactured in close tolerance jigs and fabri-cated from smooth alloy plate the inside finish is flawless making these superior in the market. Cross Country 4x4 complete front-mount kits come with 2.5" stainless mandrel bent piping de-signed to fit the best place to run to avoid damage - outside the engine bay is a harsh environment on any 4x4. The 2.5" mandrel bent piping is used so diesels receive the good flow they need to perform, this is particularly important with longer pipe-runs for Front Mounted Intercooler kits. Another design feature is the kits’ pipe work custom-designed to fit easily with the least amount of joins to limit the number of silicon joiners that can deteriorate with the presence of oil and fuel. Everything you require to fit these kits is in-cluded, from proper mounting systems to clamps, hoses, nuts and bolts etc. The whole lot is in-cluded.

Placing PWR Performance Products at the heart of the kits is a smart move because these guys have a strong reputation in the industry –

having developed several of the most efficient intercoolers in the world! PWR use a seamless

What an intercooler does for a Turbo?

Page 4 Volume 1, Issue 4

a turbo fitted, to supply your engine with more air, for more power. However, if the intake charge of air is not cooled down before it enters the engine, you will not be gaining the full benefits of your forced induction setup. Typically intake temperatures on a turbo vehicle that is running conservative boost (less than 1 bar) will skyrocket over 100 deg C. A gen-eral rule of thumb is about 8 deg C will equal 1 horse power. This explains in basic terms why you need to eliminate intake temperatures, and why you need an intercooler. Air to air coolers use a fresh supply of air to flow around the tubes of the cooler containing the compressed and heated intake air, thus removing or displacing heat. These have been the main stay as the popular choice in the performance racing industry for decades, as well as OEM manufacturers. You can divide these types of coolers into two categories: Front Mount Intercoolers (FMIC) and Top Mount Intercoolers (TMIC).

A front mount cooler is the most popular type of system employed today. A large cooler sits at the front of the vehicle for excellent air flow and pipe work leads back

into the engine bay. It’s a hard setup to beat for optimal cooling of the intake charge while the ve-hicle is in motion. That is why it is employed so much in race vehicles that are con-stantly undergoing speed and endurance. With air flowing over the cooler at the rate the ve-hicle is travelling, it’s not hard to see why these are so effective. Many car manufacturers cur-rently employ this type of system because of its

effectiveness, so a lot of people will upgrade their standard FMIC for a higher flowing unit and release the full potential of their engine. The drawbacks of such a system are the amount of pipe work you have to put into your intake sys-tem to plumb the whole thing up. A front mount intercooler requires at least 2 meters of piping fitted to the intake side of your engine and this will without a doubt cause throttle lag. Therefore, a good quality kit will have large enough pipe work, with the least amount of join-ers. Another drawback with FMIC systems is they can have a tendency to put extra load on your ve-hicles cooling system, a quality FMIC system should also be designed so that no overheating issues will occur. The other drawback to the FMIC system is air-flow and this is of primary concern to the 4X4 segment. FMIC systems rely on a steady stream of fresh air coming from the front of the vehicle to cool them down. This is fine as long as you are moving at a reasonable speed, let’s say anything over 50km/h. For a good number of off road enthusiasts, that speed may be a little excessive. Likewise, the po-sition of the FMIC poses the risk of damage due to impact, so pipe work may be routed in pro-tected positions to avoid damage or constructed from strong materials. Another problem that has been seen many times is the front-mount cooler being totally blocked with mud. This renders the cooler totally useless.

As the name suggests, these intercoolers are mounted on top of the engine. The inter-cooler is fed a supply of fresh air by a scoop in the

Front Mount Intercoolers (FMIC)

Top Mount Intercoolers (TMIC)

Page 5 4X4 Driver’s Newsletter

bonnet. They have none of the issues associ-ated with lengthy pipe work (such as throttle lag) because they can be mounted directly in line with the intake system, from turbo to in-take. TMIC systems are free from damage be-cause of the position of the mounting. There is no extra thermal load placed on an engine’s cooling system, and there is little chance of the pipe work becoming blocked with mud. TMIC systems are a popular choice for many car manufacturers because they can see the benefits of their simplicity and performance of this type of system. There are hardly any join-ing sections to fail, and they are mounted well-and-truly out of harm’s way. One downfall of the TMIC system is that they too require a steady flow of air to keep them operating efficiently. This is done in the same way as a FMIC with the vehicle speed being a factor in the amount of air flow the cooler re-ceives. Some OEM manufacturers have overcome this problem by the use of a fan on the underside of the cooler to maintain a steady flow of air, even at zero vehicle speed. Without a decent fan to pull a constant flow of air through the cooler, TMIC systems can suffer severe heat soak, caused by the heat of the engine. A FMIC will still suffer heat soak from radiated heat from the radiator at zero speeds, but not as much as a TMIC due to the fact that heat rises. With a good fan-assisted top mount, you have a cooler system that is hard to beat in the world of off road 4X4ing. With a Quality TMIC system that has been de-signed with a good fan (say at least 1000cfm) you would have the best off-road cooler combi-nation. It's got all the benefits of a FMIC, with-out the downfalls.

You have true cooling capacity at crawling speeds, instant throttle response because of minimal pipe work, and best of all it doesn’t re-circulate its cooling medium. It’s getting fresh ambient air the whole time. In Summary If you’re a hard 4X4 nut who loves pushing the limit of your truck, then a quality fan assisted top mount is the only way to go. It has just too many benefits. If you’re into some off-roading but do a fair amount of highway driving then a quality front mount maybe your answer.

Impressive as the Intercooler kit is we at G Guy Motors don’t add a product to our range with-out having confidence in its ability to perform. The Intercooler was put through its paces on our demo truck and this is what the team had to say. The kit was fitted to a TD42T engine was a great quality product and fitted straight to the engine without any dramas. All brackets on the cooler aligned to engine as expected and the fabrica-tion of the cooler itself was top spec. The fact we were able to install the first kit of this brand within the recommended time is evi-dence of its quality design and manufacturing.

Product Test: Fitting the Kit

Product Testing

Page 6 Volume 1, Issue 4

Grant’s 4X4 Driver’s Club

For more information on the Intercooler kit and other top quality 4WD products visit our website www.gguymotors.co.nz and join our 4x4 Driver’s Club to receive product information.

G Guy Motors features selective bargains on our Website and Newsletter

from our range of ARB 4X4 accessories and our range 4x4 tyres and rims.

Testing the performance improvement of the Intercooler began with a test-drive to the dyno testing facility in Petone. On the drive out the power and torque improve-ment was obvious with engine power coming on a lot earlier and stronger. Fine-tuning the engine to make the most of the Intercooler’s capabilities while on the dyno gave the best results – 17% INCREASE in torque and 15% INCREASE in Power that comes on smoothly across the rev range!

Using this extra power off-road, towing or just when driving on the open road has made a huge difference to the driving enjoyment – gone is the sluggish off-idle response. The Intercooler has kept the engine temperature noticeably down during hard-revving and given more flexibility to the way I drive as I can rely on a steady acceleration curve, springing forward on hitting the power sweet-spot. I haven’t noticed any significant loss in fuel econ-omy with everyday driving – although I am now finding I’m using the vehicle more often as my preferred choice of transport!

Product Test: Dyno Test Chart Product Test: Driving Experience

Page 7 4X4 Driver’s Newsletter

WOF Reminder Service Popular

G. Guy Motors has a professional workshop for

servicing 4WD and non-4WD vehicles. We are

mta Assured so whether you have a specialist

4WD or a family sedan you can expect a quality

service and great customer care.

Many of our customers have started using our re-

minder service where we send a letter or email

you at the relevant time to remind you of a due

WOF or maintenance for your vehicle (4WD or

family car).

Please give us a call if you would like this re-

minder service and we will load it into our com-

puterised system—taking the hassle away for you.

“Please remember, we don't just service 4WD vehicles - bring in your family car too for our

full service treatment”

Grant and his team have been busy working on

fitting a full race-proven suspension to his G Guy

Motors 4x4 Racer in time for the 2013 race season

— it features a huge length extension in suspen-

sion travel along with custom built mounts for the

new coils and shocks.

Grant’s goal is to have it ready for the next Wood-

ville 100 and later race in the Taupo 1000!

We’ll share with you the build-up, bringing to

you insights and challenges overcome as Grant

and the team set-about developing his new race-

toughened vehicle.

“For more details about these offroad racing events please see Grant’s website

(see the Events Page)”

4x4 Racing for 2013

Disclaimer The information provided in this newslet-ter is for general knowledge purposes only. G Guy Motors recommends the reader approaches their local 4WD club to gain experience with 4X4 vehicles and the correct use of recovery gear. G Guy Motors accepts no liability for in-jury, damage or expense sustained as a result of application or mis-interpretation of information provided in this publica-tion.

What’s coming up in the next issue

Our newsletter is available from our website and by clicking on “Join”

you will be placed on our mailing list

WWW.GGUYMOTORS.CO.NZ

Next Newsletter topics include:

More ARB Product Bargains

More on 4x4 Touring 4WDs

More on 4x4 Trade 4WDs

More on 4x4 Racing 4WDs

41 Old Hutt Road Thorndon, Wellington Phone (04) 472 2020 Email gguy.motors@xtra.co.nz

We’ve launched ourselves onto the social network scene with our own Facebook page to share:

ARB product reviews; Interesting stories about

what’s happening in the 4x4 scene;

Examples of our work fit-

ting products to customer vehicles;

Notices of sales or Work-

shop Open Days; Encourage our customers

to give us feedback.

And we will continue to listen to what our customers want us to share with them.

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