Intercooler for a 12HT

Damo,

Putting a 3 inch exhaust in is renowned to provide an increase in power on the 12HT.
Safe, no mods, been done plenty times before - works.

Intercooler = aluminium fabrication, testing, possible breaking a damn good motor - may provide some benefits.

Unless you can find a kit - which I've not been able to find, and you would have tried to find before posting here - I'd be sticking with the tried and true 3inch exhaust for $1200 as a pretty good start.

http://www.birfield.com/forum1.html is good place to check archives.

Tim

Firstly, a larger exhaust will be a good benefit on a turbo diesel (presume that is what you are running). The larger exhaust allows the turbo less restriction and the turbo will spool up earlier, also will give slightly more top end power.
Secondly, fitting an intercooler will also give more power as it cools the air before it reaches the cylinders. Cooler air = denser air = more oxygen = more power. ACDC is along way of track with his post, an intercooler does not allow you to run higher boost levels, it simply cools the air. You can run higher boost levels without an intercooler. It is a heat sink only. A properly matched intercooler will give you increases in power (you will notice it across the whole rev range).
A front mount will be the most effective intercooler to install, but it will be proun to bugs, dirt, and kangaroos, which not a good idea on a 4by. A top mount will be a better set-up as it will be protected for previous, but will asorb some of the heat from the motor.
Fitting an intercooler or exhaust will not require you to do anything to your fuel pump.
Hope this heaps
SantaAus