Diesel cooling options and ideas

[CrazyCooter]

I caved and finally ordered the BulletProof Aux cooler.......Hoping the brackets will work and I can just slot the skid under my OEM steel bumper for airflow? I've put this off waiting for them or someone else here to do it first.......

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[Primer Gray]

Has anyone actually confirmed the 24 grille actually makes a difference? I need to repaint my chipping black grille and was just thinking getting a flat black 24 if it actually made an improvement.

I put my original grill back on and did a run up I5 Grapevine with a full load in the bed and about 6000 pounds of loaded trailer…

The 24 grill does make a noticeable difference in how quickly the coolant gets saturated/cools down after spiking.

Even with the 24 grill, Mishimoto radiator, and BPD aux. cooler, I can still push it into cutting fuel and turbo boost on the steepest grade sections — but haven’t experienced an extreme derate event (the 15-20mph kind) since adding those parts.. even with the original grill.

The cooling stack is so inadequate that anything you do to obtain a marginal improvement actually makes an observable difference… but in my case still hasn’t fully resolved the problem completely.

I’m satisfied at this point being able to maintain at least 50mph up the majority of grades in the southwest while being loaded down and towing.

The next option on my list was a split custom built radiator ($$$$$$&&&), which I actually was willing to pursue and figure out because I enjoy the hell out of this flawed little truck so much.

 

[Primer Gray]

After combing through this thread I settled for building my own and stuffing it on my front bumper as I use my Jeep for rock crawling and off-road only. I threw 4 fans on the back as well. This solved my de-rating issues going up I-70 and other passes when towing. I also had issues de-rating when cruising (no tow) at outside temps above 100F. I am on 37"'s with factory gears.

can you share what fans/controller you used in your build.

was also considering doing this but never got around to the research and tinkering.

have you been able to ascertain a significant difference between having the fans kicked on vs. just passive airflow?

thanks

 

[suroot]

can you share what fans/controller you used in your build.

was also considering doing this but never got around to the research and tinkering.

have you been able to ascertain a significant difference between having the fans kicked on vs. just passive airflow?

thanks

The fans operate turn on/off via one aux switch. The fans dissipate more heat at lower speeds which help going up long hills. I have seen coolant temperatures reduced by >10F and held steady on long pulls. I have data logged the temp differences of 238F coolant to 260F oil at 65mph on aggressive (my foot) long pulls and became limited by turbo temps of 1600F constant at which point I had to back off.

All four fans are Spal 30103018 4" mounted to husqvarna KTM fan brackets P/N 79635943000.

 

[rharr]

I caved and finally ordered the BulletProof Aux cooler.......Hoping the brackets will work and I can just slot the skid under my OEM steel bumper for airflow? I've put this off waiting for them or someone else here to do it first.......

Keep us posted, I do enjoy your perspective on building stuff.

 

[CrazyCooter]

I got it all mounted and plumbed today.!

Had to do a little trimming on the corner frame brackets to make room for the hoses. I welded the supplied brackets to the skid plate brackets since that was the easiest. You can still get the bolts out of the radiator and/or drop the whole thing as an assembly.

Obviously I need to cut a slot in the skid plate still, but I want to see about some expanded metal with a tighter pattern or just install a bug screen inside. I also plan to fab a box on the inside surrounding the radiator and seal it with foam so any possible vacuum behind it can be utilized for extra air volume.

 

[TurboChris]

Nice! Looking forward to seeing / hearing more!

 

[CrazyCooter]

Nice! Looking forward to seeing / hearing more!

There is no doubt that it takes much longer for the truck to warm up which could be both good and bad? We added another 1/2 gal+ of coolant along with the additional heat transfer so this was expected.

I have a 2.5 mile commute to work which is why I don't drive the JT daily, but even during the winter the water temp reached 200+ before I shut the engine down........It's been 85-113° here and the water did not reach 200° on my way to work in the morning so far. The recovery time from say 220° back down to 200° after exiting the highway is super fast despite the high ambient temps we're experiencing right now.

I plan to cut a vent hole the skid plate today and see what that does. I expect it will make a larger difference in recovery and also lower temps on the highway assuming it actually gets proper airflow.........No way to really know without a wind tunnel!

I have the A/C fired up in the shop and cleaning up from Wednesday's bomb blast before I begin. Forecast is 117° today!

 

[CrazyCooter]

OK, just got it on the truck.

I cut a hole and decided to use the 3/4 expanded metal I had on hand to maximize airflow. The hole is 38% larger than the size of the radiator in hopes that the available incoming air pressure/volume would always be more than the exhaust out the back side.

I also made a little air dam to guide air from the lower part of the hole up the the radiator. The entire radiator is also sealed 360° to the vent by a foam surround. I reused the piece I cut out trimmed and flipped over for the guide.

Best I can do without a wind tunnel.......Now for the real test......It's forecasted for 117° here today!

EDIT: Pretty sure I did something right for a sheet of paper sucked to the grill when the fan is running, but falls off when the fan stops?

 

[KW80]

OK, just got it on the truck.

I cut a hole and decided to use the 3/4 expanded metal I had on hand to maximize airflow. The hole is 38% larger than the size of the radiator in hopes that the available incoming air would always be more than the exhaust out the back side.

I also made a little air dam to guide air from the lower part of the hole up the the radiator. The entire radiator is also sealed 360° to the vent by a foam surround. I reused the piece I cut out trimmed and flipped over for the guide.

Best I can do without a wind tunnel.......Now for the real test......It's forecasted for 117° here today!

EDIT: Pretty sure I did something right when a sheet of paper is sucked to the grill when the fan is running, but falls off when the fan stops?

Looks amazing Interested to hear the results, with that level of air passing through, it should make a big difference.

 

[CrazyCooter]

Looks amazing Interested to hear the results, with that level of air passing through, it should make a big difference.

I honestly can't tell much difference on the road unloaded, but it seems like it recovers quicker when coasting or pulling off the highway for sure!

I have a tow coming up with some serious elevation changes, so that will be a test.

 

[biodiesel]

EDIT: Pretty sure I did something right for a sheet of paper sucked to the grill when the fan is running, but falls off when the fan stops?

That reminds me of NASCAR. It's crazy how just an inch or two of paper over the grille can cause an engine to overheat during a race.

 

[Sweetums]

That reminds me of NASCAR. It's crazy how just an inch or two of paper over the grille can cause an engine to overheat during a race.

There's some inside joke here I'm not getting.

 

[CrazyCooter]

I just calculated the difference in core area and came up with an 18% increase from this mod. Obviously not taking into account the possible different core types since I'm not qualified to identify the difference.

Suppose the extra coolant and hose account for some heat shedding ability too? This radiator is not pre-heated by the trans cooler, A/C condenser, or CAC so there is that increase in efficiency, but it's also not seeing the volume of air through it that the stock cooling stack sees either.........

I'd say a probable 20% improvement over stock? Possibly a bit more?

 

[biodiesel]

There's some inside joke here I'm not getting.

No joke. Just a 1" x 2-3/4" gum wrapper over the grille can significantly change the engine temp in NASCAR.

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