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Old 04-27-2010, 10:57 PM   #1
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Default Inercooler Install

Earlier I posted asking for intercooler routing for top side turbo well i'm just about done. I say about because I have to install my BOV and i also am waiting for my sensor to get here so i can remove my AFM / MAF My hood doesn't currently close all the way but anyway here it is.

I ordered a kit from CX racing for $80 shipped. I had bought the intercooler 2 years ago and it had been sitting in my closet i think i got it for about $90 shipped. when i got it i was kind of mad because the fins on the top and bottom row were all bent up and so was the aluminum support. I fixed these the best i could. The package i got from cs racing had...

1x Straight
1x U-bend
2x 45 bend
3x 90 bend
6x coupler

I had to buy 1x U-bend, 2.5 to 2 reducer, & 1/2 male to male npt

I temporarily am reusing the begi-s 2" pipe. After i get rid of my MAF i'm going to redo the piping on the hot side so it's all 2.5".

I also purchased a flexi radiator hose. You can get them at a local auto store napa, car quest, checker, murray, o'rielly, etc... i used a 23" flex hose. I've read of people using the 20".

I still have my AC and PS even though the AC doesn't work and my PS leaks... i know i know i should just get rid of them..... anyway! so in order to make room for the Intercooler piping I removed that double radiator hose with the metal coupler. It gave me enough room to put my 2.5" piping with about 1/2 to 3/4" to spare from my ac/ps belt. I used 2 strips of aluminum about 8" long to secure the cooler. if you look carefully at the intercooler between the plastic bumper and the cooler you can see i made sure the aluminum was sideways so the 1"x 3/8" strip had the 3/8 side facing the front of the car so there was minimal air obstruction.

I used a hacksaw to trim all the pipe and i just kind of eyeballed and then marked with a sharpie each pipe before cutting it. for the idle bypass valve i took a 1/2" male male npt fitting and screwed it into the pipe. I put some jb weld on the threads before i screwed it in then put some more around the fitting to secure it. I'll probably weld up a new pipe when i get a new tank of argon but it'll do for now. So that's it. All said and done... not counting BOV it's ~$200

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Old 04-28-2010, 12:11 AM   #2
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Looks good dude
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Old 04-28-2010, 12:17 AM   #3
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needs more t-bolt clamps
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