Intercooler Installation

[DSM1999]

hey the other day i bought an intercooler (31x12x2.5) and i went to see if it fit inside the bumper but it doesnt look like there is a lot of space in there . there are some stuff in between. like the AD Condenser. Can someone tell me what to do or show me a diagram?

 

[4UH8ERS]

hey the other day i bought an intercooler (31x12x2.5) and i went to see if it fit inside the bumper but it doesnt look like there is a lot of space in there . there are some stuff in between. like the AD Condenser. Can someone tell me what to do or show me a diagram?

Ok, first off we are going to have to work on your grammar and spelling, because its difficult to understand what your trying to say.

2nd you need to realize what is in the way. (bumper support, bumper cover ect.) and make preperations to cut and remove what is in your way. even the HRC FMIC requires some slight modifying of the bumper support in order to install correctly and its made for the 420a specifically. so you can expect to do a little cutting in order to install an intercooler that size.

 

[Blitzeclips]

It's simple but not...

Once you remove evrything in your way, have a buddy hold the I/C while you mark the top bumper brace for drilling. Once you pinpoint a symmetrical location, drill the hole according to bolt size (threaded end also) of the actual intercooler.

Once you do that, you slide the bolts through the hole drilled and screw them into the top portion of your I/C studs/threads..

THEN, go under the car and find the mounting location, I actuall used the frame of the car.
I went out and bought some L brackets to properly support the bottom side of the I/C then fastened according to the blt pattern you marked and drilled below.

I literally took off and mounted my bumper 16 times to make room the the piping. If you look at my avatar, you'll notice the right side of my car has a blacker area to it. I had to cut the bumper and make room for the pipe. Then I sprayed it black to keep some stealth..

It's tricky to some extent but patience will help you install it the right way.
USE RUBBER WASHERS BETWEEN ALL BOLTS HOLD THE INTERCOOLER ON.

I can post pics sometime when I get out of work...

 

[bullettdsm]

It's simple but not...

Then I sprayed it black to keep some stealth..

Heh, heh. Hey Blitz. You don't think that big ole intercooler in front kind of gives you away ?

MB

Sorry, couldn't resist

 

[Blitzeclips]

Haha. Good one. I like that..
Yeah I think it gives me away just a tad. But think of how many get fooled by the black piping!

None.

 

[VelocitàPaola]

even the HRC FMIC requires some slight modifying of the bumper support in order to install correctly and its made for the 420a specifically.

Slight... hell, not only did I have to hack the fascia, I had to cut open the bumper support and make a new bracket for it on the driver's side. At least I didn't have to make any brackets for the intercooler itself, that thing is mounted solid.

For that reason alone, I recommend the Hahn FMIC over anything. Alas, you've already bought a different intercooler, so all I can say is make careful measurements, and only drill when necessary. I'd be weary about cutting into the chassis or sub-frame... when at all possible, bolt the IC brackets to pre-existing holes. If anything, drilling into that radiator support shouldn't be too detrimental.

I found a jig saw or circular saw with a wood cutting blade worked best for cutting the bumper support. My dremel and a cut-off wheel seemed to work the best for cutting the fascia.