Problem with Koyo 55mm Install
 

So I got the radiator in today. It's currently sitting in the garage while I chill out after fussing with the install. The new radiator is currently sitting in the Miata but it doesn't look right to me. The top edge sits further away from the AC condenser than the bottom edge. I believe the metal tabs on either side of the radiator pointed out in the photo below are the culprits. I could bend the one on the passenger side out of the way but the one on the driver's side as something bolted to it.

I'm thinking the previous owner when installing the intercooler they moved the radiator and AC condenser back in the enginebay? The radiator seems to sit really far away from the front.


http://i389.photobucket.com/albums/o...koyo_tab_1.jpg

http://i389.photobucket.com/albums/o...koyo_tab_2.jpg

http://i389.photobucket.com/albums/o...ems/koyo_1.jpg

http://i389.photobucket.com/albums/o...ems/koyo_3.jpg

Yeah that looks pretty far back to me, including the AC compressor. I think the mount brackets have been relocated. My radiator setup has not been stock for awhile but IIRC the radiator is very close to or up against that shelf the runs left to right just behind the latch.

^ as he said, the radiator should be very close to the front bay shelf thingy. Less than an inch away, I think. There's no way of routing intercooler pipes between the rad and the shelf without tilting it back a ways.

http://revlimiter.net/blog/wp-conten...9/DSC_1778.jpg

There's my wife's NB. The radiator sits very close to the shelf. The little piece of foam is less than an inch thick.

Thanks guys for the confirmation and photos. I think this has probably gone beyond my skillset and will have to take to a tuning shop to install a different intercooler. Ugh.

What supercharger/intercooler setup is that. If the intercooler is from trackdog just give them a call they are great help.

Well, the previous owner bought it back in 2005/2006 when BRP was still around in South Carolina but I think they closed down. I went through the receipts and both the Supercharger and Intercooler are from BRP. I have a feeling the intercooler is a knock-off of the Track Dog Racing setup.

O well good luck then :(

BTW I typed compressor above but meant condenser.

I do not think you need a new intercooler, unless it is damaged or something. I think you can make it work as-is as an 'over the top' setup. Use slim mount fans on the back to get clearance between the back of the radiator and the engine. Stock fans will not fit as you have probably seen. Mine in my NB is at least as far back as yours, if not more, and I fit two Spal 11" slim fans in there. They work fine.

A/C condenser already looks like adapter brackets have been made to hold it in its new position so it may be OK.

Intercooler looks like it is mounted? Hard to tell. The shelf behind the latch has already been modified to bring the hoses straight up and over the radiator. So the IC may be good to go as-is.

So it looks like you need a support to hold the upper part of the radiator. There are several different ways to do that. Take a look at some of the threads here on DIY front mount intercoolers (FMIC) for some ideas. Once you do that you just need a shroud to seal that large gap between the top of the radiator and the metal shelf. That forces the air flow to go through the radiator and not over the top of it.

You may also need to come up with a new upper radiator hose but that is not too hard. You just have to spend some time behind the counter at Auto Zone perusing all their radiator hoses. Been there, done that :)

I am elbows deep in getting my Miata back on the road but could help later if you are not in a hurry. Looks like you already know DVCN and I am in the SA area also.

Send a shot of the lower brackets if you would, particularly where they are attached to the chassis. I'll bet they have been relocated aft as well.

Seriously though, read through all of the FMIC threads here you can find, especially the over-the-top setups. They contain lots of information and lots of pictures.

I took some more photos last night. The current intercooler setup shroud fits fine over the Koyo like it did with the stock fan. I connected all of the hoses up to it as well (they were just pushed out of the way in the photos).

http://i389.photobucket.com/albums/o...oler_plate.jpg

http://i389.photobucket.com/albums/o...oler_plate.jpg

http://i389.photobucket.com/albums/o...o_no_space.jpg

I still cannot tell if the lowers are relocated, probably have to see it in person. But since the shroud fits, and everything else is mostly figured out, you just need to fit some fans in there and work on sealing up all of the gaps in front of the radiator as much as possible. I do not see any reason why you cannot make that Koyo work with your present IC.

Even after all of that, if you track it in the summer, you probably still want to consider adding the Carbontrix extractor scoop or something like it. It really helps with getting air through the radiator by lowering pressure in the engine bay.

I'll see if I can get some photos tonight or tomorrow of the lower brackets.

Comparison photo if anyone is interested...
http://i389.photobucket.com/albums/o...mparison_1.jpg

No worries, more curiosity on my part. The main thing is that the Koyo fits except for maybe the fan clearance. Do I have that right? If so you are almost there. You need to get some good beer and have DVCN and I over :)

You are correct, John. Everything fits except for the current Flyin' Miata fans that were in there with the stock radiator. I got the good beer covered. :cool::rofl:

OK man then I think that win is within your grasp. Get two 11" or 12" slim mount fans. Spals are known good quality, ebay no-names are cheaper. siliconeintakes.com sells cheap electric fans as well. Check out some of the fan threads here for names of sellers, etc. Just be sure they are slim, like 2.5" at the highest point IIRC.

Though I used 11" fans, there was a bit of room left over, and IIRC cjernigan was able to get 12" fans to fit on his. You may not have room for a shroud and will have to mount them right up against the radiator, with some padding of course to prevent chafing on the cores.

Where at in SA do you live? Looks like not a big deal.

I10/Huebner area

OK wait a minute... do you have these fans?
http://www.flyinmiata.com/index.php?...0%20%201990-93

If so, those already look like slim mount fans, with a minimal shroud. Mine has a DIY shroud albeit not very deep, and probably the same Spals. So something else is going on. Either your radiator is thicker than mine, mounted farther back, the standoff mounts are longer, or something else is interfering. Mine is a tight fit with the shrouds. It barely clears the sway bar. I should probably get a look at it if you are up for it.

I am right on the edge of having my car running again (should be back online this weekend) so maybe I can drive it over there for side-by-side comparison. I spent a ridiculous amount of time designing/fabbing this v-mount radiator setup of mine, and its predecessor versions, so I am pretty intimate with the NB radiator area.

Sure, that'd be great to get a side-by-side comparison to see what's up. I'll send you a PM.

Beer? Did someone mention beer? Maybe we can get some Chachos take out too!