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1G Custom 1g side mount intercooler using Bell/Garrett core

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benspilk09

10+ Year Contributor
128
68
Feb 16, 2010
Little Rock, Arkansas
I've been looking for a hahn/dejon/alamo SMIC for my 1g for the past year or so and have so far come up dry, so I'm starting to explore other options.

I could build my own, but I don't have access to a TIG welder and hate to buy one just for this project.

Does anyone want to build me a custom 1g SMIC using a qulaity 5-6" core, which will mount in the stock location with minimal butchering of the body? For the prices the old ones have been bringing, one could probably make a few bucks turning out a small batch of them. The last dejon one I found that I missed out on went for $500, and I'm sure a modern core is WAY more efficient.

I don't want an FMIC because I have a/c, want to keep my stock fans, stock appearance, and don't want to run into overheating problems.

Thanks!
 
Likely gonna have to be a bell core as garret didin't really have anything in the size range. I did one last fall. Was a major pita to do. We did the biggest core that would physically fit in the space, and the end tanks were really hard to do. because of it. Of course I didn't have an 1gb AWD mockup car here, and used a 1ga fwd, and the subtle differences in the chassis caused some fitment issues. If a big core is what you want, prepare to spend some $$$. If I was to do another it would be simply replacing the stock core with a better one. Trying to jam a big one in there isn't fun.
This is also probably a good oppourtunity to look at an a2w down in the stock spot. Could easily add a trans cooler based heat exchanger on front of the condenser, with minimal cutting/impact to engine cooling. Probably would be the best way to make a sidemount intercooler work.
 
If I was to do another it would be simply replacing the stock core with a better one. Trying to jam a big one in there isn't fun.

This is basically what I had in mind. Something similar in form factor to the stock intercooler, but using a modern, more efficient core, and going to 2 or 2.5" piping. Would you be able to build a jig from a stock side mount? I could handle building my own brackets to mount it, so long as some mounting bosses were on the core/end tanks somewhere.

Also, do you have pics of the side mount you built? I can't find anyone else that's attempted a project like this.
 
Likely gonna have to be a bell core as garret didin't really have anything in the size range. I did one last fall. Was a major pita to do. We did the biggest core that would physically fit in the space, and the end tanks were really hard to do. because of it. Of course I didn't have an 1gb AWD mockup car here, and used a 1ga fwd, and the subtle differences in the chassis caused some fitment issues. If a big core is what you want, prepare to spend some $$$. If I was to do another it would be simply replacing the stock core with a better one. Trying to jam a big one in there isn't fun.
This is also probably a good oppourtunity to look at an a2w down in the stock spot. Could easily add a trans cooler based heat exchanger on front of the condenser, with minimal cutting/impact to engine cooling. Probably would be the best way to make a sidemount intercooler work.

This is basically what I had in mind. Something similar in form factor to the stock intercooler, but using a modern, more efficient core, and going to 2 or 2.5" piping. Would you be able to build a jig from a stock side mount? I could handle building my own brackets to mount it, so long as some mounting bosses were on the core/end tanks somewhere.

Also, do you have pics of the side mount you built? I can't find anyone else that's attempted a project like this.

I would be interested something like this as well. Are there actual differences between the stock FWD and AWD intercoolers or differences between 1GA and 1GB?

If this is something you are willing to look into, I have a stock 1G intercooler laying around that could be lent out to see what could be done. I may even have an old Dejon sidemount laying around, but has a junk core due to damage (would have to see if I could find it in storage first though).
 
The only difference was in the 1990, likely because it never had to account for an auto transmission. All other 1G side mount intercoolers were there same.

Great.... once again the 90's being the bastard children of the DSM world. So I assume the only real possibility is to have an actual 1990 intercooler re-cored if wanting to stay side mount?
 
Wow, I've never noticed it until now, but yeah there are 2 different styles of 1g intercoolers out there. The bottom inlet is different, and the mounting points are different. I believe the 91-94 style is on the right.

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Great.... once again the 90's being the bastard children of the DSM world. So I assume the only real possibility is to have an actual 1990 intercooler re-cored if wanting to stay side mount?
I don't think you're that limited, especially with all the fab work you're already talking about. Just know that the intercooler inlets are a little different and you can work around it from there.
 
I have a clean Alamo 1g SMIC on my car now. Would be willing to take it off and sell it to the right person :p
 
I've been looking for a hahn/dejon/alamo SMIC for my 1g for the past year or so and have so far come up dry, so I'm starting to explore other options.

I could build my own, but I don't have access to a TIG welder and hate to buy one just for this project.

Does anyone want to build me a custom 1g SMIC using a qulaity 5-6" core, which will mount in the stock location with minimal butchering of the body? For the prices the old ones have been bringing, one could probably make a few bucks turning out a small batch of them. The last dejon one I found that I missed out on went for $500, and I'm sure a modern core is WAY more efficient.

I don't want an FMIC because I have a/c, want to keep my stock fans, stock appearance, and don't want to run into overheating problems.

Thanks!

We are in both very similar situations. I would like to keep the my 1991 Eagle Talon TSI as stock looking as possible. I just found this after doing some research:

Forge VW 1.8T Alloy Side Mount Intercooler – UroTuning

I would pursue this now, but I'm in the middle of restoring the interior and don't have the funds to allocate to this right now. Some time next year, I will be concentrating on performance. What I might end up doing is purchasing this aftermarket VW Side Mount and taking it to fabrication shop. Let them whip up something, then have them do it to a few others and I would sell them.
 
I have considered modifying a VW one as well, but the cores don't measure much larger than the stock 1G SMIC.

There used to be a company selling them using a 5" or 6" core from Garrett or Bell, but of course they are very expensive. Once you spend $500-700 on a core and then have it modified, you may as well just buy a blank core and have the end tanks built from scratch.
 
Has anyone come up with an idea for an upgraded sidemount for 1g?
Or anyone have one for sale?
If so message me
 
I recently bought a 1ga AWD Talon. I am pretty interested in doing this, but how much power could a large SMIC support? Anyone have a formula for intercooler size vs hp capacity?

Would a liquid to air intercooler in this area be better? I have the fab skills, tig welder and CNC plasma in my shop.. I just need to gain some of the design knowledge.
 
If your looking for a starting point start checking out the Toyota Supra Mark 4 side mount.

This side mount is capable of handling up to about 400HP.
 
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I modded a large VW golf sidemount once with good results with a B16g
 
Whats goin on with this? Is the target still 600$+

I had a trust surpa super side mount. With any supra sidemount you have to cut and flip the end tanks on the intercooler.

Actually got scammed on my first one from fellow member. He took the end tanks and swapped them. But put it back together with rtv and didn't think I would notice. I was pissed. I kept the Intercooler and got my money back on that deal.
 
Whats goin on with this? Is the target still 600$+

I had a trust surpa super side mount. With any supra sidemount you have to cut and flip the end tanks on the intercooler.

Actually got scammed on my first one from fellow member. He took the end tanks and swapped them. But put it back together with rtv and didn't think I would notice. I was pissed. I kept the Intercooler and got my money back on that deal.
I don't think anyone is bringing this to market at this time. I am debating making one to see how it does, but am also thinking about a water to air setup with heat exchanger.
 
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