BOV on the Intercooler
 

I have a DSM 1g BOV and an ebay intercooler (18x12x3 and 10x12 core) and ive been thinking about modifying it to have the BOV mount directly to the cold side end tank. I know they do this sort of thing on subaru's from the factory, but im a little worried about the walls of the tanks being too thin. I guess i could solder nuts onto the inside.

http://all.dejonpowerhouse.com/edit/...-BOV_small.jpg

Put a vaccum on "blow" attached to the inlet and plug the outlet before you start drilling. It would be simple enough to fabricate a gasket out of the standard material you can buy at PepKraAutoNapa.

Drill out the opening and drill/tap 2 holes for the bolts and you're set. Nothing fundamentally different about using the IC vs. a charge pipe to mount the thing. End-tank thickness is certainly thicker than any charge pipe I've seen and made of aluminum... no need to worry about integrity.

I thought about doing this, because my IC pipe routing is such that finding a spot for the bov flange was gonna be tough. the reason I decided against it is that if you want to change your bov in the future, now you have a flange welded to the IC, and it's much easier to completely replace a small section of IC pipe. the unhappy compromise I had to make was putting the recirc valve on the hotside of the IC pipes.

I considered doing this as well. Only disadvantages are the BOV is more exposed to the elements up in the front of the car vs. under the hood. I'm afraid that water and dirt will make it stick over time. And then it will be a pain to service as mine is between the radiator and A/C condenser for stealth. I will be putting my AIT sensor in the outlet end tank though. Probably put the BOV close to the TB for protection against the elements and ease of service.

It works. Ebay fmics typically have pretty thick endtanks too.

http://i295.photobucket.com/albums/m...s/IMG_1837.jpg

It does make it simpler with such a flat surface and all.

Where can I find more info on your setup?

damn very interesting set up you got...

You guys missed out, he has the only V mount on this board.

and it sounds like a subie lol

Lots of nice stuff in that picture... V-mount, custom intake, CAI, tubular exhaust, external wastegate, modified bumper, coolant reroute, COPs, possible 5-point harnesses... That car is the poster child for mt.n!

+1 on the thick end tanks on the ebay ICs. I have one I bought from CXRacing and the end tanks were thick enough for me to tap the intake temp sensor threads directly into the wall. It was no problem. With the BOV you might consider using helicoil inserts for the mount screws (since the tanks are aluminum) but otherwise it should be easy.

Maybe the only running v-mount setup, but others have mocked up the materials.