Well let me first start off by saying this is fairly easy and the process is almost self explanatory. I feel this is a very worthwhile mod and on my 16G works very well. You can find the IC in junkyards or from your local big truck fixin' place. The piping can be had from RRE or you can probably get it from Home Depot. Here is a pic of the IC and the piping.
You will need:
10mm socket, wrench and extension.
14 or 17mm socket(Ican't remember for sure)
Phillips screwdriver
some heavy duty wire ties or thin sheetmetal
NPR intercooler
4 90 degree bends 2.5" in size
small section of straight 2.5" pipe
couplers and clamps
JB Weld to bead the pipes
Step 1: Remove the front bumper by using the 10mm socket and wrench and remove all the mounting bolts. There are 2 on each side, one at the very end of the bumper where it meets the fender and one above the sidemarker. There are 5 along the top of the bumper where the hood latch is. Then if your car has been a body shop like mine that's probably all that is holding the bumper on, or there may be a few more bolts in yours. Look under the headlights and unbolt them to get the bumper off the rest of the way.
Step2: Use the 14 or 17mm socket(I'm sorry I can't remember exactly what size it is) to remove the 4 bolts holding the crash bumper on. Pull it off and start removing the plastic ducting with the phillips screwdriver.
Step 3: unbolt the power steering lines from the radiator support and tuck them behind the support, use some zip ties to keep it from flailing around. Now is the time to mock up the IC where it will actually go. With all that crap out of the way it tucks up nicely to the radiator support. You can use some soft material to cushion the back against the radiator support and the outlets against the frame at the bottom. After it's where you want it, wire tie it in place and now you can measure to make your brackets. Use the holes on the radiator support where the plastic used to snap into and the mounting holes on the IC itself.
Step 4: Now that it's hung it's time to pipe that thing. On a T25 you will need to hack off the elbow so the outlet points down. With a 16G you will need an actual J pipe, not a 1G outlet pipe. Use some JB weld to bead the pipes. You will use one 90 degree bend to go down from the J pipe or the outlet and head towards the driver side of the car. Then using another 90 degree bend to come out from the driver side outlet on the IC and toward the passenger side of the car. Use the straight section of pipe to connect these two together. Now use the remaining 90 degree bends to come out and toward the passenger side and then over and up to your UICP. Connect everything and you're almost done.
At this point it should look something like this.
Now you just have to trim the crash bar so it doesn't interfere with the IC and you can trim the plastic to fit around it but you don't really need to. Now just start putting stuff back together. Bolt the crash bumper back in and reinstall the bumper cover. Here are some pics of it after the bumper is reinstalled.
This pic is so you can see what it will look like on a 2gb, it is not my car and belongs to ColonelFox from the other boards.
Well that's about it for the install, straightforward and simple, just like most like it. If you have any questions email me or get with me on AIM. Good luck and have fun.
