Front Mount Intercooler Kit (suits Ford PX/PX2 Ranger and Mazda BT50)

Introducing the latest addition to the Process West 4x4 Enhancement series: the TERRATUFF Front Mount Intercooler system, specifically tailored for the Ford Ranger PX1/PX2 and all models of the Mazda BT50 3.2. This system is crafted with a focus on leading-edge performance and OEM-grade durability. It boasts a design akin to that of the manufacturer, ensuring a seamless fit and finish, backed by extensive testing and validation for unparalleled quality.

By installing the Process West TERRATUFF Intercooler system in your Ranger or BT50, you are choosing the pinnacle of charge air cooling technology. This results in marked improvements in power and torque, offering a product that withstands the rigors of time and use. This is the essence of the Process West TERRATUFF philosophy.

Ranger/BT50 TERRATUFF Design Elements:
The core of the Process West TERRATUFF Intercooler system is its robust, front-mounted Bar and Plate intercooler core. The TERRATUFF intercoolers utilize Bar and Plate construction for its superior cooling efficiency and heat-sink ability, coupled with unmatched durability and impact resistance. The Ranger/BT50 TERRATUFF core, measuring 700mm x 247mm x 75mm, significantly enlarges the cooling surface area and thickness.

The TERRATUFF system resolves the common issue of piping integrity found in intercooler upgrades. It employs specially molded four-ply silicone hoses, combined with high-strength constant tension hose-clamps and mandrel-bent aluminium pipework. This results in a product that matches factory standards in quality and reliability.

A key feature of the TERRATUFF design is the isometric rubber mounts for the intercooler core. In extreme conditions, such as intense off-road use, these mounts enable the intercooler to flex with the vehicle, mitigating strain on the mountings and pipework. This innovative approach greatly reduces the chances of cracked mounting brackets and hose connection failures.

The Process West TERRATUFF intercooler solution is a testament to serious, long-term performance demands.

Ranger/BT50 TERRATUFF Testing Process:
Process West's engineering team eschews traditional dyno testing, which doesn't fully replicate real-world conditions. Instead, they have adopted a practical approach to validate the TERRATUFF design:

1. A Ford Ranger loaded with 650kg of concrete blocks.
2. A standardized 4km uphill run with a 310m elevation gain.
3. Maintaining a speed of 80km/h using Cruise Control.
4. Utilising a racetrack-developed AIM datalogging system for comprehensive cooling data.

This test, conducted with both the factory and Process West TERRATUFF intercoolers under identical conditions, revealed significant differences. The factory intercooler peaked at 49C, while the TERRATUFF system only reached 28C, marking a 43% improvement in cooling efficiency. This translates to noticeable increases in torque and power, and a reduction in EGT figures, contributing to a longer and healthier engine life.

Summary:
The Process West TERRATUFF Intercooler system stands out in the market through its rigorous design, development, and testing. Its efficiency and durability have been proven in real-world conditions, making it ideal for heavy-duty off-road usage or towing across Australia. The Process West TERRATUFF is your go-to solution for reliability and performance.