Car: 92 GSX

I purchased a Buschur’s FMIC Kit and was doing the install over the weekend and ran into a little problem. To mount the intercooler I had to enlarge two openings next to the radiator for the inlet and outlet. The enlargement of the holes was finished with little problems. When I was mounting the intercooler, I noticed the right side won’t fit in the hole because the power steering lines are in the way.

Does anybody have this FMIC or similar setup? If so, how did you install it?

Any feedback is appreciated.

You have to remove the PS cooler and lines and just route the hose back to the reservoir. I have been running without the cooler for a while now, you can also look into an aftermarket cooler and AN fitting and lines and mount it where your fog light is.

I just cut mine at the end of the PS cooler and bolted it back on. Now there is just a small curve, and I have had no problems with mine either.

A friend just bought a Buschur FMIC and asked me for some assistance with cutting the holes for his intercooler on his car. I really wanted to say no because it was a pain when I did mine. For mine, I used tin snips and a jig saw, the jig saw was basically worthless. I spent a lot of hours snipping and grinding mine until it was large enough. I know there has to be an EASIER way to do this.

How did you guys enlarge your holes?

A hole saw w/ drill

project_tsi said:

A hole saw w/ drill

Click to expand...

We really can’t use a hole saw because there already is a hole there. We need to enlarge the two holes next the radiator (somewhat triangle shape), the hole where the power steering and AC line got through. The hole needs to be enlarge 1/2" - 1" off the top and two sides.

Die grinder and carbide burrs would be ideal, regular metal grinding stones will work as well but it will take a lot longer and an ear plug is probably a good idea.

how about a saw zaw?? I just cut a little slit in the metal and pushed the P/S cooler lines up. Worked perfectly.

tbTalonES94 said:

how about a saw zaw?? I just cut a little slit in the metal and pushed the P/S cooler lines up. Worked perfectly.

Click to expand...

tbTalonES94, I'm pretty sure you live a couple of complexes down from me. Goldfinch? I have the blue GSX, I just posted a pic under my profile.

Sawzaw? Is that what you use to enlarge your holes? It looks like you have about the same intercooler as me, so you probably had to enlarge the same holes.

Yeaup that's me. Name is Trevor. Your GSX is nice! That 3" exhaust sounds very good.

Yea i used a saw jaw (carefully) to enlarge the holes. Isn't too tuff. We should get together sometime and shoot the shit. I had intended to introduce myself the day we both were getting out mail but i was kinda in a hurry . See ya around

Die grinder and carbide burrs

Click to expand...

Thats how I did mine.

i used a dremel with carbide cutting tip. you definitely want to use earplugs.

tin snips eh.. i have a pair of those. I just bought the same core and sat there for 30 minutes today scratching my head when i removed the front bumper . "I'd sell my soul for a dremel" ::waits patiently::

Although a dremel might take a while longer compared to a die grinder

When I saw "purchased a Buschur's FMIC" my first thought was dayyeem, somebody is still willing to shell out over a grand for a front mount when there are cheaper and not really worse options. I 'm not implying ebay kits and such and should 've really said "option".

Anyway, to add something constructive for archive purposes I personally enlarged those holes with just a big, sturdy flat tip screwdriver and a hammer. I wouldn't say I 've spent much time or energy doing that and it wasn't too painfull. Just punched through the part where the metal is thinner and hammered/bent away the rest. My in&out piping is 2.5" I should add and with a 3" piping it would have been a different story.

Back to the thread.. I have the core that I bought for $100 from a local guy, but it looks like im gonna have to cut into the sub frame, i'll most likely need to use a sawz-aw due to how thick the sub frame is. I'm confused on whether to cut it on the bottom of the piece facing the ground, or the top towards the top of the hood. Since there were no pics on this thread, anyone have any that can help me out?

talon2gbuyer said:

What is even more funny about this, is that your flaming me for a "worthless comment" and yet you do the exact same thing. Eat your own words Hipocrite.

Back to the thread.. I have the core that I bought for $100 from a local guy, but it looks like im gonna have to cut into the sub frame, i'll most likely need to use a sawz-aw due to how thick the sub frame is. I'm confused on whether to cut it on the bottom of the piece facing the ground, or the top towards the top of the hood. Since there were no pics on this thread, anyone have any that can help me out?

Click to expand...

There should be no cutting of any subframe when installing a FMIC in a 1g, or a 2g I believe, but I dont work on many of them. The subframes are no where near where the intercooler installed. An enlargening and cutting of the "D" shaped holes are whats needed. And some trimming of the stock bumper support if need be, I did it to make the intercooler sit flush and not extend below the bumper, I also have an ETS, but its based on the same design FMIC.

In SOME cases, the buschur fmic included, cutting of a portion of the front subframe (which houses the radiator and ac condenser, so how exactly you think an fmic is no where near that is beyond me..) so please, before making yourself look like a giant jerkoff, do your research on the topics subject matter. Saves us all from having to explain it to ignorant people who can't so research, because if you did, you'd know the fmic I'm talking about is damn near 3 feet wide and 7 inches tall. So where the fmic connectors are on it, is right where the front subframe is. Hence having to cut a portion to squeeze the ic pipes by.

If I put the ic plumbing through the top holes near the radiator, I'd have to cut half my bumper apart for it to get any airflow.



To the mods: sorry for back to back posts, tapatalk won't let me upload two pics at the same time.

6 posts deleted, warnings given....the name-calling ceases or the thread gets closed.

Also, that's a Punishment / CXRacing intercooler core for a 1G, not a Buschur core for a 2G.

talon2gbuyer said:

You must be logged in to view this image or video.

Click to expand...

Sorry, I was confused, but I think you used the wrong terminology for that part. I am not a jerk off and have done my research. I try and use the correct terminology so people do not get confused and know exactly what I am talking about.

It is not considered the subframe, its the unibody frame of the DSM. The subframes are what bolt into the uniframe.

1g front subframe:

1g rear subframe:

Ah @Justin thank you for clearing that up.

@agent: your right, I got it confused . But as its a 1g core I can't use it anyway :rofl: now I get to go punch the seller in the face .

It's a $185 core, so you didn't get ripped off....just resell it and buy the right thing.

CXRacing Bar & Plate Intercooler Core Eclipse 1G

Yea I got a hold of the guy who sold it to me, he's gonna take it in trade for a set of ams 880cc injectors