Simons GU TD42

Hey guys

thought id start my build thread since the build has officially started.

This is the day i picked her up, 02 TD42T manual 214k on the clock.
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was obviously a family bus previously but has a few minor things done
-Dual batteries
-roof mount LCD (not really useful for me atm)
-narva driving lights
-tjm winch bar
- 2 inch coils (unsure of shocks)
had some hideous wiring so that was the first project, took most of the first weekend to sort out the fire hazard under the dash.

Now to the build. tonight i started my power/reliability mods

The list includes
-IAT and EGT sensors Running off a single Auber digital gauge
-Top mount intercooler (200x380) dunno what the factory nissans ones were but this one was free and will be an easy to fit.
-IC fan
-Port and polish the exhaust manifold. just mild to increase boost response.
-3 inch exhaust

All of this with the aim to increase power, torque and responsiveness.

first up the IAT sensor.
(excuse the crap phone photos)
Using a k type thermocouple with a 1/8'' NPT gland.

Drilling and tapping the intake manifold.
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i chose this point coz its close to the inlet of the manifold and has meat (the bolt hole was for a loom clamp)

Fit the gland.
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Fit the probe and gland nut and admire your handy work while you finish your beer.
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ill try keep this thread up to date.

next up is Exhaust manifold, egt probe and port polish.

Nice work, keep the thread going.

very nice you seem to know your way around an engine.
Good pick up on the wagon too

I'm interested to know how you have wired up the two sensor to the one Auber guage? I have Auber gauges and got a air temp sensor, with the same idea to run it switched with my water temp probe.

Thanks fellas yeah love patrol so far, dream come true.

As for the sensors k type thermocouples, for the most part, have a range of 0-1000c So more than suitable for egt and iat.

The wiring is simple. Common negative for both sensors straight to the gauge. Then the positives from each gauge, Through a switch. (In my case a 2 position 3 pole rocker)

The more sensors you have the more positions you need on the switch.

There is one downside to external switching, any preset alarm values will remain so you cant have seperate alarm values for each sensor. (May be an issue if u want alarms for water temp and IAT)

That's pretty much how I thought it would work and planned to do mine. Wasn't sure if the settings would need adjusting in the gauge, I couldn't see why but hadn't looked to far into it myself. Still need to get an intercooler, then I might go pre and post cooler as well as water temp.

Pre and post would be excellent for determining cooler efficiency.

As long as you use the same sensor type youll be sweet.
Just remember use a good quality switch as any excessive resistence will give inaccurate readings. If you plan on running more than 3 sensors consider a rotary switch.

Update:

Ive been plodding along over the past few days, this is what ive achieved;

tapped the bleed hole in the thermostat housing to fit a water temp sender.
These gauges are highly accurate an reliable, only down side is the thickness of capillary.
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Turbo and exhaust mani came off and i started the work on it.
Enlarged the ports slightly and smoothed off the casting, didnt want to go overboard and risk durability.

The casting on cylinders 1,2 and 3 was reasonable and only needed minimal work. mainly in smoothing the lumps on the corners.
4, 5 and 6 needed more work, the corners were irregular and one point was a good 1.5mm smaller than the port on the head.
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Here you can see the lumps, i didnt get any before photos but they where very intrusive and i believe, restrictive.
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Now i have to finish off the manifold (egt sensor) and remount it.

Hey gents (and ladies)

Everything is back together (for now)
in typical nissan style, first turn start.
There is a boost leak somewhere which i will admit sounds pretty insane.

ive finished the egt and iat sensors and installed the gauge.
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Havnt been for a run yet but at hot idle im getting 100ish egt and 40ish iat.
im not overly pleased with gauge mounting atm, i just wanted to get the sucker mounted.
will have to do some trimming and stuff to get it sitting flush.

the other addition....
Attachment 44390
very pleased with this one.
bought it s/h off another forum member.
has onroad and offroad maps, dvd, ipod support, usb input and a reversing camera (yet to be mounted).

please excuse the horrid photos, im not real keen on taking the slr into the shed.

still to come is boost and oil pressure gauges. maybe next week.

then its time for more boost and sort the intercooler :)

4x4 concepts sell left and right hand pillar pods if that's of any use to you

Was seriously considering a pillar gauge pod but the budget wouldnt allow. Ended up with a generic 3 gauge pod which i will velcro in the centre of the dash and cut a hole in my dash mat

some here have 2 x 52mm gauges sitting in front of the
speedo cluster on the steering column

Nice ride!

Quote:

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Originally Posted by threedogs

some here have 2 x 52mm gauges sitting in front of the
speedo cluster on the steering column

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Thats i neat spot, im just going to go right in the centre above the aircon vents.

Ive had the chance to do some baseline runs to see where my temps are at.

At warm idle im seeing approx 100 degrees egt and about 40 degrees iat
general cruisy driving about 50 degrees iat fairly stable and anywhere from 200-350 egt.
on one run where i was trying hard to get some peak figures i got 601 egt and 87!!!! IAT

i think its time for this baby to go in!
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Hey mate,
Just put some gauges in my rig,$150 off ebay for a pillar pod and fits a treat and looks factory as!!

Quote:

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Originally Posted by MYR1G

Hey mate,
Just put some gauges in my rig,$150 off ebay for a pillar pod and fits a treat and looks factory as!!

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Yeah i looked into pillar pod but the cost did it for me, im trying to do things like that on the cheap so i can spend more on really important things like tyres... and beer :cheers:

the triple pod i got was 17 bucks and i kinda dig the look sitting front and centre.

Nice work on the mods. That stereo looks good too Simon. :)

Quote:

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Originally Posted by 4by

Nice work on the mods. That stereo looks good too Simon. :)

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it really does :049:

Update time. ive been abit lazy lately but got a fair bit done in the last week or so.

The biggest job was installing a new stereo. 4 channel amp and 4 new 6.5 inch splits. super duper happy with the result.

Now to more practical progression.

The most exciting improvement is the intercooler setup, all but done just need to make up a bracket for some extra support.
I fabbed up the pipe from the turbo outlet to the IC, and ive re used the nissan rubber joiners on that side.
the cold side is just a 51-64mm elbow into the manifold
i machined up the stock nissan flanged elbow so its just a straight 2.5inch barb about 40 mm long. came up really good.
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Only just realized its not sitting level there haha. but there is plenty of room underneath. might even fit fan in there at some stage.

another mod ive started is fitting out the tail lights so they are functional.

As ive mentioned before this build is done so on as tight a budget as i can manage so i have more cash for big ticket stuff like tyres and more cash to get away and enjoy what we all love.

intercooler setup im pretty proud of budget wise. total cost to date... $27
admittedly i will need to fork out for a bonnet scoop but im hoping i can get a 2nd one (maybe a wrx scoop)

Looks very neat intercooler set up. Im also looking for bonnet scoop thinking sti to keep the opening bit higher.

Thats why im leaning towards the subie scoop aswell, they are nice and tall and should suit width ways. I also looked at a plastic scoop in super cheap which looked okay.

Update time.

sorry no pics this time round.

Finshed off the intercooler and its working a treat (even without a scoop) seeing a steady 35 degrees Iat.
ive ordered a fibreglass scoop of fleabay. d22 navara style.

biggest addition lately is the 3 inch mandrel exhaust. i had some fitment issues with the dump pipe but was an easy fix.
I went with straight through with 1 resonator, sounds great. one of the best notes out there.

tail lights are almost done, just need to wire up the right side.

was almost finished fitting the gauges when i found the capillary on the temp gauge is too short!!
so they had to come out again.

Time for some pics

Intercooler setup all buttoned up and painted black
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Snorkel on and plumbed up.
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Gauges all but done and uhf installed
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Scoop on and painted. i need to rub it back it back and paint again, (not happy with the finish)
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Looks good mate. Just curious, what sort of paint did you use on the intercooler? I'm asking as, you're adding a layer on top of the bare intercooler metal, that may jeopardize your cooling effectiveness.

Etch primer and acrylic black, relatively light coats. 1 of each

theres a video test from the guys at MCM between bare alloy and painted black intercooler. (im sure i saw a discussion on here about it)

The black was actually more efficient due to the higher emissivity coeffecient of the color black, the real benefit is low speed driving where air flow is limited.
And i dont want to run a fan if i can avoid it. I have IAT sensor so ill see if there is any truth to theory in practice.

Good stuff buddy. Looks like you've done your homework. I wanted to point it out since my mate painted his D22 IC with just your typical rustkill black from bunnings. Needless to say his temps went up, and eventually, he realized why.

the thing with emissivity is it works both ways. im not familar with the d22 setup but if the cooler is close to the motor or is subject to high under bonnet temps it will absorb that radiant heat and reduce the cooling efficiency. also if you apply heavy coats it may "insulate" the core and reduce heat transfer.