1. Join the Community!

    DSMtuners is a massive archive of DSM information - but more importantly, it's a COMMUNITY! Join in and participate with other DSMers, and invite all of your DSM friends to make this place their home. Chat with others, create a build thread, post questions and answers. Get involved! Logging in will also remove many of the advertisements, along with this notice. ;)

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

Posted by benspilk09, Aug 9, 2020

Please Support VR Speed Factory
Please Support ExtremePSI
  1. benspilk09

    benspilk09 Proven Member

    87
    43
    Joined 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!
     

    Street Build 365  4

    1991 Eagle Talon TSi AWD
    awd · manual · 1G DSM
    Loading...
    ErikTande likes this.
  2. bastarddsm

    bastarddsm Proven Member

    5,277
    1,100
    Joined Aug 26, 2003
    Mendota, Illinois
    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.
     

    Showcar Build 6K  1

    1991 Eagle Talon N/T
    9.805 @ 144.00 · 1G DSM
    Loading...
    SouthIndy_Talon and ErikTande like this.
  3. benspilk09

    benspilk09 Proven Member

    87
    43
    Joined Feb 16, 2010
    Little Rock, Arkansas
    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.
     

    Street Build 365  4

    1991 Eagle Talon TSi AWD
    awd · manual · 1G DSM
    Loading...
  4. SouthIndy_Talon

    SouthIndy_Talon Proven Member

    119
    41
    Joined Jul 1, 2014
    Greenwood, Indiana
    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).
     

    Street Build 911  1

    1990 Eagle Talon TSi
    fwd · manual · 1G DSM
    Loading...
    ErikTande likes this.
  5. 19Eclipse90

    19Eclipse90 DSM Wiseman

    4,840
    627
    Joined Sep 29, 2003
    OKC, Oklahoma
    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.
     
    SouthIndy_Talon likes this.
  6. SouthIndy_Talon

    SouthIndy_Talon Proven Member

    119
    41
    Joined Jul 1, 2014
    Greenwood, Indiana
    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?
     

    Street Build 911  1

    1990 Eagle Talon TSi
    fwd · manual · 1G DSM
    Loading...
  7. benspilk09

    benspilk09 Proven Member

    87
    43
    Joined Feb 16, 2010
    Little Rock, Arkansas
    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.

    3-jpg.jpg
     

    Street Build 365  4

    1991 Eagle Talon TSi AWD
    awd · manual · 1G DSM
    Loading...
    19Eclipse90 likes this.
  8. talon749

    talon749 Proven Member

    78
    8
    Joined Sep 19, 2004
    Chillicothe, Illinois
    I always thought it would be doable and cool to adapt an upgraded Jetta intercooler like this.
     

    174  1

    1991 Mitsubishi Eclipse GST
    fwd · manual · 1G DSM

    298  0

    1995 Eagle Talon N/T
    manual · 2G DSM
    Loading...
  9. 19Eclipse90

    19Eclipse90 DSM Wiseman

    4,840
    627
    Joined Sep 29, 2003
    OKC, Oklahoma
    I don't think you're that limited, especially with all the fab work you're already taking about. Just know that the intercooler inlets are a little different and you can work around it from there.
     
  10. bastarddsm

    bastarddsm Proven Member

    5,277
    1,100
    Joined Aug 26, 2003
    Mendota, Illinois
    Intercooler is the same, but the chassis is different that when you are trying to get a core in there with almost 2x the frontal area, it f***s it all up. :(
     

    Showcar Build 6K  1

    1991 Eagle Talon N/T
    9.805 @ 144.00 · 1G DSM
    Loading...
  11. six40

    six40 Probationary Member

    6
    0
    Joined Feb 14, 2010
    Brantford, ON, Canada
    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
     

Share This Page

Support Vendors who Support the DSM Community
Boosted Fabrication ECM Tuning ExtremePSI Feal Suspension Fuel Injector Clinic Jacks Transmissions JNZ Tuning Kiggly Racing Morrison Fabrications OHM Racing Raven Fabrication RixRacing RockAuto RTM Racing SouthBay Fuel Injectors STM Tuned Track Decals Track Sculptures VR Speed Factory