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Im gathering some ideas about putting a front mount on the stagea. Im looking the pros and cons about same side outlets to reuse the existing pipes too.

One other issue is the shape of the intercooler. Something like an XR6 intercooler seems to have a quite good surface area up around ~1400cm^2 over the stock ~380cm^2, however with the license plate and bumper, a more square intercooler looks like it will be at a disadvantage with airflow.

A longer, thinner intercooler seems to be a better option, as there is a wide, but not very high opening at the bottom of the front lip. But that comes with a disadvantage of surface area. To match the above surface area of the XR6, it would be more like 70X20cm = 1400cm^2.

However would less surface area be better if nearly all the surface has a stream of fresh air?

Any thoughts

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I'm just going to fit the justjap 'no holes' return flow fmic kit. It's tried and tested, proven and allows you to retain your airbox making it totally legal (in Vic anyway).

Custom is always a little nicer, but I'd be betting by the time you're done fabricating the core and piping, it'd be more than double the jj kit..

Sorry just read that you plan on retaining stock piping....might be worth fabricating the core after all. Will be watching this thread ;)

Edited by gts_koop
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I bought a cooling pro fmic from just jap and it uses the original piping holes and it works great you gave to do a few minor adjustments to your front bar and relocate your horns and trans cooler if you have one but other than that its good. Good price easy fitment.

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why not use a 1 side in 1 side out 600x300?

You could always use a 180° silicone joiner on the drivers side and squeeze it in between/under the intercooler and radiator. (this setup will cover the bottom grill in only the cooler, and shouldn't see the return pipe)

I've just bought a 180° silicone joiner, and I'm picking up a whole lot of random intercooler piping this weekend. All second hand.

Just measure everything before you buy anything (saved me money on 4 different intercoolers), I've been measuring and screwing around with ideas for a few weeks, and from what I've seen. If you mount the cooler hard under the top bumper support plate it will finish right on the bottom lip of the bumper cutout, so you will have 3-5cm of clear space under the cooler to the bottom of the bumper.

Mine will be almost identical to adams new cooler setup. Most of those return flow coolers have outrageous claims to pressure drop and psi capabilities, with some google searching you'll see what i mean.

This is information from what I've seen and measured, I'll be testing it all out when a good cheap cooler comes up.

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I purchased a second hand blitz cooler it was return flow factory piping and awesome piece of gear. Don't get why anyone would use anything else. Doesn't do the right angle under the cooler sends piping back and around then back in original hole.

Sounds interesting. Any cutting involved?

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