The Intercooler Thread

[StageZilla]

I removed that uner bonnet insulation thing

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my engine is bloody loud enough, and i dont think its gonna get any quieter

[Tangles]

Started my installation last night, will keep going thru this week (nights) and get it finished. taking photos as I go so will post up a complete writeup.

So far so good, mind you the 10mm bolt holding the bumper bar on, above the sidemount intercooler, was damn hard to get to. Thats the problem when you are over 2metres tall with saucer-type hands!!

Brendan

[AMS]

Im thinking of doing somethin like this, but not to this extreme.....

[StageZilla]

Im thinking of doing somethin like this, but not to this extreme.....

<{POST_SNAPBACK}>

can u make the pic abit smaller it takes too long to load up

and u cant see shit cause its so dark

[Tangles]

Well, thats a BIG hole there showing off the intercooler. Too big in my opinion.....

You wouldnt belive it for a non-spannerman like myself; last night I mounted the cooler with string, measured up the pipes, and cut them to suit. Just 4 cuts with an angle grinder and filed back to get rid of the little burs.

Put the bumper on over the top, and it looks wicked!! The cooler is exactly the right size, it sits at the opening of the Dayz kit (got to cut away the numberplate mount) and the 2 big spotlights will fit up perfectly either end!

Photo's will be up when the install is finished. Tonight Im using 4xclamps per join plus hi-temp silicone adhesive, so will have it all bolted up and start putting back on the bumperbar.

On a downside - use glasses when anglegrinding! Got a metal laceration to my eye last night so had to stop (eye was weeping too much to see properly)!!!

Brendan

[StageZilla]

Well, thats a BIG hole there showing off the intercooler. Too big in my opinion.....

You wouldnt belive it for a non-spannerman like myself; last night I mounted the cooler with string, measured up the pipes, and cut them to suit. Just 4 cuts with an angle grinder and filed back to get rid of the little burs.

Put the bumper on over the top, and it looks wicked!! The cooler is exactly the right size, it sits at the opening of the Dayz kit (got to cut away the numberplate mount) and the 2 big spotlights will fit up perfectly either end!

Photo's will be up when the install is finished. Tonight Im using 4xclamps per join plus hi-temp silicone adhesive, so will have it all bolted up and start putting back on the bumperbar.

On a downside - use glasses when anglegrinding! Got a metal laceration to my eye last night so had to stop (eye was weeping too much to see properly)!!!

Brendan

<{POST_SNAPBACK}>

haha, good stuff, hope u plan on mounting the cooler abit more securely than string though

i reckon its very satisfying to do it yourself and even if u struggle and have trouble, at the end u know it was your own work, and as long as its not dodgy then u should be proud)

shops wanted $800 -$1000 for my ally intercooler piping which is a bloody rip off and a half, but thats life

[Tangles]

Thanks mate.

Yup, its secured with some bent metal pieces, you'll see them in the photos. Just had a long strip of 4mm thick (hard) aluminium, bent and shaped it to suit, drilled some holes, and bolted it up to the plastic surround of the fan using standard bolts/holes.

Very secure, doesnt move at all. Nice work 'Guvna!

Very satisfying to do it myself using a $200 pipe kit from USA of ebay, polishd 2.5inch aluminiu 6061 grade. 2 x straight pipes, 2 x 90degree, 2 x75 degree and 2 x 45degree angled pipes, plus silicone tubes and clamps.

Way better value than the $800 I was consitently quoted around Adelaide.......... but my 2yr old wants me inside to play with him. =(

Hopefully It'll be finished by Thursday night and photos can go up here on the board for everyone to drool over!! lol.

Brendan

[AMS]

Yeah Sorry about the small picture Thats all I could do I think I'm goignt o have to get a DAYZ bar though

[Tangles]

Well, as the below photo's suggest, Ive finished the Apexi intercooler installation - 3 nights worth, roughly 8hrs in total working at a realistic pace (for an inexperienced installer!).

Not left with any left over bolts or nuts or screws, besides those used for the stone guards, as I had to leave this entire under bumper stone guard off due to the pipe installation.

I probably could have cut two pipes 1inch shorter and put this stone guard back on, but maybe another day, when I need to flush the intercooler out (say in 40000kms time)!

But still, doesnt look half bad at all.... very pleased with my effort, considering Im a turbo 'home mechanic' noobie. Only thing Im not happy with is the fact that the intercooler is 1inch too far to the left and doesnt sit perfectly square and therefore 'look balanced', but never mind.

I think it looks pretty good, with the bigger front bar opening and the spotlights sitting either side of the cooler, in their standard position.

Wasnt a hard job as such, & would do it again without a doubt - its something all of us can do with a bit of time and some basic tools.

Hope the post is of some help...... Brendan

[AlexCim]

Wow, that worked out GREAT!

Dammit i want a DAYZ front bar heaps now. Will suit my application perfect, i guess its something that may just work itself out in the future.

[Tangles]

Thanks Alex, was very happy with my effort. Cheers for the big backslap!

BUT, took it for a testdrive last night at 11.30pm, and ended up limping home. See photo 3 across, 4&5 down. The LHS pipe join was dodgy (I knew it when doing it up), as I cut the pipe too short at the corner, and was 'forcing' the 2 pipes together at the join.

Under pressure it didnt work and popped off. So tonight I'll recut a new pipe (75degree angle at centre) around 1.5inches longer, and that way I wont be forcing the 2 pipes together at the join.

We'll find out soon enough if there are any other weakpoints.

Brendan

[Ska]

Yeah Well done Brendan! Nice work!

[Tangles]

Thank you Cyrus (Ska), thats appreciated. I'll tell ya's, its amazing how much of a higher satisfaction level you get from doing it yourself.......

Hey SK - want to employ me now as your race-team intercooler extraodinaire?

Brendan :lol:

Edited November 2, 2005 by bwilkeson

[CoolPC]

Well done mate, looks like she's coming together nicely for you

[Tangles]

Well done mate, looks like she's coming together nicely for you

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Cheers Rob! (coolpc).

In case ppl didnt know, I bought the Stagea from CoolPC in July 2005.

[AMS]

Well done Brendan...Looks fantastic mate Now all you have to do is give me a copy of your DAYZ bar

Cheers,

Chris

[Tangles]

Thanks everyone for the nice comments.

Well last night I fixed up the popped pipe connection, just swapped the 2 pipes around and it worked out great.

Car runs very well, and seems to have a bit more power as well. =)

But, Ive decided Im not happy with the quality of the silicone tubes, and the clamps are terrible as well, so Im going to buy 4ply silicone tube and much better quality clamps, and redo each connection.

No hurry to do this, but I dont think it would work well with these cheap silicone tubes with a rebuilt hiflowed turbo & 15psi.

OH - everyone note, if using silicone based adhesive, make sure it is ok for use with O2 sensors!

[Tangles]

Well, today's the 11/11 so its my b'day, so I took yesterday and today off. yay to me......

Anyways, was able to spend another hour on it yesterday redoing all the silicone tube fittings. I used the brand 'ThermalFlex' which is very thick blue 4ply silicone tube. Great stuff. Thanks to nottieboy & justjap on ebay for helping me out with tubes and 'Tbolt' clamps.

My clamps & silicone tube that was with the pipe kit (colour red) were absolute crap, pipework popped off 3 times. Now its totally redone and WONT be popping off.

Moral of the story - use good clamps!

Brendan

[beastien]

I'm thinkin of gettin one of the Blitz LM cooler kits, normally you have to remove the airbox and fit a pod, but i want to keep the standard airbox.

I was thinking i should be able to shorten the pipes to meet up with the factory piping where the factory IC was originally.

Does anyone see a problem with this?

[AlexCim]

Nope, sounds like a good idea actually

Good luck with it.