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DIY Intercooler Finished!!!

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Old 04-10-2007, 01:41 AM   #1
bigedog8
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Default DIY Intercooler Finished!!!

well after many hours of work (although I feel it was a very fun install personally), pissing around with piping and cutting my bumper support and another hole in the fender well.... with a Dremel.... It's on! complete finished pics to come, my camera ran out of F'ing batteries and its too late to take pics now. I gave her a very very small amount of go pedal on the way home and it started goin lean so I can't boost it w/out a tune now.....but I'll get that fixed very soon and after i install my 75mm tb/plenum that gets here tomorrow.

If anyone has any questions or wants me to do a write-up of my install just lmk. I see there is already a sticky on IC installs so I didnt waste time typing everything out but if you need details lmk.

here are some pics.. I will add the completely finished pics tomorrow

MMMM.... pretty

here's how you get from this:
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To THIS!!!!!!!!!!

Yes you have to cut your bumper support there.... with a dremel and cutoff wheels it takes a good amount of time LOL!

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ZOMG the snail moved to shoot air downward!!!!!
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arbitrary piping routing pics.
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Ya thats a hole I had to cut..... And yes it somewhat saddened me to cut holes in my car....until it was all bolted up. pipes got a bit scratched but hey, air still moves through them so I could care less...plus all others need to see is taillights not my intake piping right?
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ya so its not mounted perfect... but u can't tell with the bumper on so who gives a ****!
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Old 04-10-2007, 02:53 AM   #2
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Default RE: DIY Intercooler Finished!!!

Very cool, now swap pullies, get a tune and cook some tires =)

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Old 04-10-2007, 02:02 PM   #3
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Default RE: DIY Intercooler Finished!!!

very nice work. how much did you end up spending?
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Old 04-10-2007, 02:09 PM   #4
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Default RE: DIY Intercooler Finished!!!

for everything right there... not including my boost pipe and the couplers im gonna replace.... like $250 bucks and lots of time lol
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Old 04-10-2007, 05:04 PM   #5
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Default RE: DIY Intercooler Finished!!!

where did u find all the piping and rubber couplers you used... because I need to extend my intake from dragging on the ground to up into my fender.
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Old 04-10-2007, 05:12 PM   #6
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Default RE: DIY Intercooler Finished!!!

http://cgi.ebay.com/ebaymotors/3-Int...QQcmdZViewItem

thats the exact kit i bought. if u need 2.5 the same seller has 2.5 also. it wasnt a bad deal and I still have like 3 extra pieces left over.
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Old 04-10-2007, 05:24 PM   #7
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Default RE: DIY Intercooler Finished!!!

how long did it take you?
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Old 04-10-2007, 05:30 PM   #8
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Default RE: DIY Intercooler Finished!!!

hmmm. I'm gonna estimate around 6-8 hours or so.... give or take, It was a 2 day leisure project so it was on-off sort of deal. unbolt some stuff. do some cutting. go eat easter dinner. work more then go inside for an hour or so to rest.... so it was hard to keep track of, but maybe 6 hours of total work. now if I would have had a torch or angle grinder w/cutoff wheel. it would have taken significantly less time, keep in mind I used a dremel to cut all that **** out lol. bumper support took a long time to cut. had to cut some pipe too. because re-clocking the intercooler is just cut an allen key down and undo 6 bolts,turn the s/c and bolt it back up. piping really wasnt too long. my buddy was helping me out doing the discharge side so it didnt take long. but he only helped about half the time of working on it so it was mostly only me since he had work on monday and I had no class.

If you had the right tools for cutting and worked hard (we were drinking beer pissing around most all the time because thats a necessity to work on vehicles and have fun doin it) it probably wouldnt take more than 3-4 hours tops.
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Old 04-10-2007, 11:09 PM   #9
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Default RE: DIY Intercooler Finished!!!

you have a battery relocation i'm assuming? 8 hours isn't much at all really.
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Old 04-10-2007, 11:26 PM   #10
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Default RE: DIY Intercooler Finished!!!

very sexy. i think im going to do this myself as well. did you leave the maf on the intake side of the supercharger or you going to move it to a blow through, that way you can run a nice bov
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Old 04-11-2007, 12:03 AM   #11
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Default RE: DIY Intercooler Finished!!!

nope leaving the maf where it is for now. dont really wanna bov... if you couldnt tell I am going for the sleeper (or however much of a sleeper a gt can get, but it seems like the sohc 4.6 is underrated a lot these days), and I actually am getting some notice from others on town, my buddy said theres people posting stuff about me on a local forum lol. saying i think its supercharged but nothings done to it so I dunno haha.

no battery relocation at all. my piping comes nowhere near the battery and it has plenty of ground clearance.

here take a look ahaha, got my pics of the finished front now. i know the bumper flares down a bit but ill fix that by either trimming it or moving it up somehow. but i had to slap everything on there to get home in time for school so i gotta do stuff as open time comes.

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Old 04-11-2007, 12:12 AM   #12
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Default RE: DIY Intercooler Finished!!!

very nice fella. yeah, my car has a nice sleeper look to it. til you start it and hear the blower and the entire car shakes from the heads and cams. i may have to get down on a DIY intercooler. i'm assuming you didn't even have to lift the motor out either. after i get my fuel system in this month, i don't really want to trust 600+RWHP to just meth.
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Old 04-11-2007, 12:48 AM   #13
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Default RE: DIY Intercooler Finished!!!

oh hell no to lifting the motor out lol. it was easier than installing the supercharger imo. it was not bad at all. like i said i enjoyed it. all it is is some cutting bolting and then routing piping, only place that needed to be cut for piping was the passanger side for the pipe to run down to the intercooler, theres a pic above. other than that, everything else just routed nicely, bought the piping kit and had to cut a few but in the end it wasnt bad at all. once i get it all cleaned up with a lighting iat and clean up my hoses and all, I will post up more pics of under the hood complete. it was not bad at all and i highly recommend doing it, its pretty gratifying too fabbing your own stuff. just dont do all of the cutting with a dremel and it will save u lots of time hahah after i ran out of the badass reinforced cutting wheels i had to do it with the regular ones... i dont know how many i broke/wore down and had to change. hahaha but where theres a will theres a way I tell u. worked out good in the end
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Old 04-11-2007, 03:58 AM   #14
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Default RE: DIY Intercooler Finished!!!

could you tell us how much of each piping that you used and couplers. like 2 - 75* elbow, 2 - 90* coupler etc.

thanks !!
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Old 04-11-2007, 12:04 PM   #15
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Default RE: DIY Intercooler Finished!!!

i'm tempted to get one of them kits on egay and try this out. i'd like to make it so i don't have to do any cutting and chopping up of the car though
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Old 04-11-2007, 12:38 PM   #16
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Default RE: DIY Intercooler Finished!!!

that looks great. I cant wait until my piping comes in and I can get started on mine. Arent you supposed to bolt the I/C to the top of the bumper support though? Doesnt look like its up far enough. Im the same way though. Ill just get it on there first and fix it later...
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Old 04-11-2007, 11:00 PM   #17
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Default RE: DIY Intercooler Finished!!!

I like it mounted right where it is... It could be up higher but I don't want a different bumper and u need air to flow across the core otherwise it doesnt do a whole lot. right now the inlet in the bumper (which has a flap on each side to funnel air, youll see what im talking about) so all of the air that enters there has to flow right through the middle of the core for good cooling. if i had a diff. bumper i could mount it higher but thatd show it off more and I don't really want that since its somewhat of a sleeper car, hence why i got the sq which is the quietest of the vortechs.

I'm pretty sure its-(ill double check)
3 straight pieces of piping. 4 if u include the little 6 inch on on the intercooler to extend it out to make the bend
2 of the 90 ish pieces of pipe-both coming off the cooler.
1 45 degree pipe cut short (this is the pipe connected to the TB)

7 straight couplers
1 90 degree bend coupler
1 45 degree bend coupler

I also have the smaller coupler on the discharge side still on the vortech. I cut it real short and shoved it all the way on the blower... doesnt hang over. and then clamped the 3" coupler on there. u will need a coupler that downsizes from 3 to 2.5 to use only one coupler if u have 3 inch pipe.

Now. also when doing this depending on how your setup is now. I have the iac in the pipe right before the TB. pics to come. but I bought a lightning iac because it is threaded and you can tap that pipe and install it so it doesnt leak. that is what i am working on right now. my bypass is also hooked up to that , i just made a small hole and stuffed the hose in there, im getting a bung welded within the next few days, ill have pics of that all when its done too. and its getting tuned at brenspeed on the 27th!!!!!!!!!!!!!


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Old 04-12-2007, 12:54 AM   #18
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Default RE: DIY Intercooler Finished!!!

Quote:
ORIGINAL: bigedog8

thats the exact kit i bought. if u need 2.5 the same seller has 2.5 also. it wasnt a bad deal and I still have like 3 extra pieces left over.
really?!

could you send me the pics of what you have left over, I might be able to use them and send you some $$!

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Old 04-12-2007, 01:02 AM   #19
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Default RE: DIY Intercooler Finished!!!

This is a little off-topic but I havealways wondered, how do you setup a BOV with a supercharger?

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Old 04-12-2007, 05:03 AM   #20
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Default RE: DIY Intercooler Finished!!!

any finished product pictures with the boost pipe and bypass valve attached?
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Old 04-12-2007, 05:03 AM
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