I don't really post a lot on this board, and I guess it's because I feel like my weeksauce supercharger pales in comparison to some of the sweet *** turbo installs I see here. However, I did want to share an intercooler install that you may or may not have seen before. First off, let me say this. $135 shipped. Clamps, Pipes, and Intercooler. Not bad for a nice size core. Needs a little fine tuning as far as exact pipe size, but not too shabby for only taking about 5 hours. I kind of copied part of the design from Track Dog Racing. I would have gone their route on the passenger side of the intercooler as well, but if I would have done that, I would have needed to either take out my A/C condenser, or have an intercooler that had a top mount exit. Since I have neither of those, I had to go the route that I did.



The driver's side pipe goes straight down, and then has a 90º turn into the side of the radiator.



Because I opted to use an existing hole (seen in above pic), and not move my radiator like TDR does, I needed to notch the support that's in the hood to allow it to clear the pipe. I also flattened out a little bit of the bottom part of the pipe that drops down so it would fit flush on top of the radiator.



The passenger side drops straight down to the bottom of the car, hooks under the radiator and has an upward bend on the two 90º elbows bringing it right into that side of the intercooler.



Two 90º elbows hooking into the intercooler.



You can see the pipe go into the intercooler on the bottom, and see it travel straight up into the engine bay to hit the blower.



Needs a little sanding, but the cuts were perfect, no damage to the top part of the hood. This was probably the scariest thing I've done to the car.



Beautiful isn't it? Need to rotate the clamp on the bottom left, but other than that, it's in and done cept for a few minor adjustments.

 

Looks good, I plan on a similar setup when I boost my car, but with a top exit intercooler passing over the rad on both sides.

How much did you have to flatten that one pipe to be flush with the radiator? Just a few taps with a hammer?

 

Wow looks good. Nice over the rad setup.

 

how much space do u have with the hood trimmed? id like to do that on both sides but im not sure bout clearance. What size pipe ru using?

 

Well, I didn't use a hammer... I actually marked the area that needed to be... "reformed" with an "X" using my sweet *** blue utility knife. Then I went into my front yard, and beat the **** out of my car trailer with the pipe. Worked great. Looks like **** on the bottom, but it is smooth still. I would say that I formed it 1/4" to 1/2" in, above the radiator, and above the top mount for the radiator. Car trailer 1, intercooler pipe 0...



2.5" pipe. I would say that there is 1/2" with the hood closed. Under some full-power runs this evening it has a little scratch in it from yet ANOTHER structural piece on the hood, below the other 2. It only needs to be dremelled out about 1mm, then there will be over 1/2" of play, even when the engine torques up. Big thing on the left side is:

A. You'll need a top exit intercooler, not cheap.

B. Without a top exit, it would be a royal pain in the *** to move the condenser far enough out of the way to get it to come out the top. And realistically, that's with the top exit too. I had to move my condenser about 2-3 inches over.

 

AC is getting torn out neway...

And yeah im looking into a top exit intercooler neway

 

nice. im glad you posted this because im going to be doing something similar with the piping.

 

http://cgi.ebay.com/ebaymotors/CXRac...mZ330267050693
http://cgi.ebay.com/ebaymotors/_Car-...=p4506.c0.m245

That is what I plan to use, they aren't all that much at all. I'm not sure which size I want to go with though.

I like your forming method haha, very inventive.

 

piping looks too low on the passenger side. i'd cut some pipe differently to bring it up before you rip it off. Otherwise it looks good.

 

I agree...should be almost level with the ground.

speaking of, level off the IC core itself while you are at it.

 

You guys ever hear of boost loss with a supercharger? It seems like I lost about 2.5psi when I put the intercooler on... Is that something typical with the supercharger, or does it seem like I might have a leak somewhere?

 

Yeah you will loose some boost from adding an IC, though that sounds kinda high. It pumps the same amount of air no matter what. But when you place a restriction (the intercooler), there will be a net loss in flow. Second, the IC also cools the air, which makes it denser. In doing so, it causes the pressure to drop also. Combine the two, and yeah you will see less boost. Though it's certainly a good idea to check for leaks. However, If you had one you would probably have a bad idle too unless it only leaks under boost.

 

I've seen 2.5-3 psi on an Intercooler that does not flow as well. I find normal is 1.5psi loss due to pressure drop. YMMV

I also had an A/W which had a 1psi pressure drop

 

I have a feeling I have a leak.

Symptons...

After I installed the new pulley I was driving to a friends house and I stupidly hit the gas. I forgot to turn overboost off post install and the car bucked like crazy. immediately afterwards the car won't go below 2k rpm.

Gotta be what it is. What's the best way to determine where the leak is coming from? Ether spray?

I was thinking that something changed in my MSPNP settings all of a sudden, but now with everything combined, that sounds like the problem. It would also explain why a quick blip of the throttle would cause it to hesitate, and why it's slow to slow down in revs after I let off the throttle idling. Not too mention, all the bucking from overboost could have easily caused something to just simply fall off... Ether it is. On to walmart!

 

check all your couplers, one blew off the pipe.

 

 

I don't remember exactly, but my Starion intercooler was something like 50 shipped from eBay (it was in much better shape when I first got it). Sure it was used but it's all the same.

http://farm4.static.flickr.com/3069/...9250bd58_o.jpg
http://farm4.static.flickr.com/3151/...ce91d991_o.jpg

Yeah my bumper looks like ****

 

Looks like the automatic vacuum line that is plugged on 5-spd cars was the culprit. I had to plug it up, and now the car is idling better and seeing some higher boost numbers. The 90º going into the engine needs to be replaced though because it collapses under idle. Anyone know where the best place to get a few aluminum 90º bends is?

 

Actually, a good muffler shop can make almost any piece you want. And they are usually pretty darn reasonable.

 

So the intercooler lost me about 1.7-2.0 psi.

My total now is 14psi at 7200rpms. I haven't gotten to check the ambient temps, I need to order the kit from DIY to eliminate the MAP. I'm guessing at speed, with a cool night (like right now, perfect weather!) in the 99º range.