Front mount intercooler

[tstkl]

I have a jonny race car front mount intercooler and it is the perfect height to fit where the ac compressor on my car was, and im trying to move it as far back as possible, but now that ive cleared all the obstructions on the car itself, the upper and lower intercooler pipes are the only thing that are in the way (they are hard pipes and dont allow the intercooler to move back any farther) has anyone cut their intercooler pipes easily and succesfully? what did you use? also i need about an inch and a half off the lower pipe, but theres really no where i can get that inch and a half from except the intercooler itself, the alternator prevents the pipe from moving back any farther... any reason why cuting the rear facing outlets on the intercooler would be what a bad idea... any thoughts are appreciated

 

[Boosted98gsx]

do you mean the A/C Condensor? The compressor is on the back of the engine...

 

[tstkl]

yea, my bad, you know what i mean...

 

[Bryan90TSiAWD]

grab a handheld hacksaw or a sawzall (sp?) and itll cut right through it.

 

[ckgtimk1]

seems like a lot of work just to mount it a few inches further back, its easier to cut a bumper, than to cut and re-weld an intercooler. but if you are set on doing it, getting new intercooler pipes custom made would probably be easier. you might have trouble sealing up you're intercooler after hacking it up. just my thoughts.

 

[tstkl]

i think you dont understand what im doing, let me explain

see pic 1, that thing is 2.5 inches long, i need about 1-1.5 inches less of it... thats what im cutting... no welding involved...

 

[tstkl]

grab a handheld hacksaw or a sawzall (sp?) and itll cut right through it.

my only worries with a hacksaw is that the cuts wont be straight...and a sawzall would probably be worse in my hands...(....)

after i do make the cuts, what should i use to flare it at the ends? or do i need to?

 

[DSMcrazy3]

There will only be couplers there, it shouldn't matter if the cut is straight, just as long as all the way around, there is enough room for the coupler to be clamped on firmly. I would think if it's 2.5 inches, you would be fine cutting off 1.5.

 

[Boosted98gsx]

also make sure you can still roll that pipe for couplers, otherwise you're gonna be raisin hell when your hose couplers pop off. That's not exactly an easy place to get to with a ratchet/wrench.

 

[1993eclipseGS]

It doesn't matter if the cut will be straight, As long as the coupler fit's on it and there is enough room to clamp it down. You do not need to make a lip on the end, Just buy t-bolt clamps.

 

[tstkl]

im not sure what you mean by that being a hard place to get a rachet or wrench, but i guess the only thing im really worried about is making the rivit in the end, i have t bolt clamps or whatever so i guess ill be fine, theres plenty of room since i cleared almost everything out...

 

[i1nk83]

you can also make beads out of jb weld. thats what i have on my ic pipes and have had no issues whatsoever. even with t-clamps there is still a risk of the pipes blowing off if there isnt some kind of bead. trust me i learned this the hard way

 

[nijle4u]

Wouldnt it be cheap just to take it in somewhere and have it cut down? It'd be perfectly done then and i cant imagine they'd charge you that much, an exhaust shop could do it in 5 mins.

 

[HighPsi92GST]

Wouldnt it be cheap just to take it in somewhere and have it cut down? It'd be perfectly done then and i cant imagine they'd charge you that much, an exhaust shop could do it in 5 mins.

If he has a saw to do the cutting what would be the need to take it somewhere to have it done unless he has 2 broken arms and no one else around him knows how to operate a saw? Why pay anyone any amount of money for something so easy?

As far as the beads on the ends of the pipes, everyone seems to have different opinions. Some say a tbolt clamp will hold without a bead, others have had them still pop off. When someone said it would be a hard place to get to, they meant if one of your pipes blows off along the road, its not going to be as easy as some other setups to just stick the ends back together and quick tighten the clamp.

Good luck