Garrettba03 Member 78 Member For: 13y 7m 21d Gender: Male Location: Sydney West Posted 30/09/11 12:27 PM Share Posted 30/09/11 12:27 PM (edited) For all you people who buy second hand coolers or just purchased the intercooler without kit and are thinking...how the hell am I going to put this in??I just installed an intercooler with all piping, mounts, everything made by myself.Not easy and you need to be good with tools but I managed to fit a 300*600*100 core in the ba xr.There are some comprimises but for the price it cost me, im happy to live with the comprimises.CoreThicknessCorner of bar needed to cutGrinded corners and inPick of top mounts and ac pipe bent upPic of small brackets (flat steel) used to lift up ac radiator for ac pipe clearanceDriver side ac lift bracketBottom cooler mounts bolted to radiator support next to power steer cooler (power steer cooler brackets were bent back paralell with intercoolerPipes inClose up driver side, oem coldside pipe under headlight cut just past boost sensor, hotside oem cut to fittop finishedReassembledCons...lost spotlight drivers side to intercooler pipe (I couldnt care less), hangs a bit low, trimming needed to bumper round pipes.I wanted to retain underboonet factory ill be painting all the pipes and cooler and brackets black, rounding all the sharp corners of brackets etc cleaning it up. For those who dont mind its easier to run the pipes next to radiator passenger side and replace factory pipes.Also forgot to say radiator top brackets have to be moved back about 15mm for ac condensor clearance Edited 30/09/11 10:47 PM by Dagabond Link to comment Share on other sites More sharing options...
Dillz Three pedals are better then two.. Donating Members 15,637 Member For: 17y 8m 11d Gender: Male Location: Melbourne Posted 30/09/11 01:09 PM Share Posted 30/09/11 01:09 PM Damn, was going so well until the retarded cold side piping..Why not just throw it up straight to the TB, all that unnecessary piping just loses you throttle response and power. By the time the air changes direction and goes all the way back your probably achieving fark all. Link to comment Share on other sites More sharing options...
Worm A much better forum Silver Donating Members 3,808 Member For: 16y 6m 14d Gender: Male Location: Victoria Posted 30/09/11 01:12 PM Share Posted 30/09/11 01:12 PM What did it cost? Was it much cheaper than the process west stage one? Waste of time and money in my opinion... Cutting the sh*t out of stuff... Dicey rubber bends everywhere..Good on ya for having a crack, but leave it up to the pros I say!!! Link to comment Share on other sites More sharing options...
Garrettba03 Member 78 Member For: 13y 7m 21d Gender: Male Location: Sydney West Posted 30/09/11 01:19 PM Author Share Posted 30/09/11 01:19 PM Lol I know tell me about it...that screwed me had me scratching my head for a bit. Always wanted to keep the underbonnet stock and decidedif it means more pipes...ohh well what do you do Did not want to loose the snorkel so ended up with....spaghetti! Link to comment Share on other sites More sharing options...
Garrettba03 Member 78 Member For: 13y 7m 21d Gender: Male Location: Sydney West Posted 30/09/11 01:21 PM Author Share Posted 30/09/11 01:21 PM (edited) cost intercooler $175 (dunno how I got it so cheap)cost of bits and pieces $250Total $425 Edited 30/09/11 01:22 PM by Garrettba03 Link to comment Share on other sites More sharing options...
Dillz Three pedals are better then two.. Donating Members 15,637 Member For: 17y 8m 11d Gender: Male Location: Melbourne Posted 30/09/11 01:22 PM Share Posted 30/09/11 01:22 PM I reckon you've come this far you could quite easily fix it.Run the cold side up to the TB and clean up you engine bay, loose the cross over and whip up an intake. Bugger stock it won't even look turbo'd! Link to comment Share on other sites More sharing options...
Garrettba03 Member 78 Member For: 13y 7m 21d Gender: Male Location: Sydney West Posted 30/09/11 01:35 PM Author Share Posted 30/09/11 01:35 PM Hehe yeah I thought about that especially the length of the piping and diameter of stock pipes only 2 inch! but didnt want to change things too much, ive had so many modified turbos over the years and im over cleaning k&n filters, pods, cant just go to ford/peps/autobarn and buy a part cause everythings custom. On the cold side ive gone from intercooler 3inch, silicone reducer 2.75 to 2.75 pipe, then 2.75 to 2.5 reducer and 2.5 pipe, then 2.5 to 2 inch reducer to factory under light pipe to gradually bring the pipe diameter down. Link to comment Share on other sites More sharing options...
MiKa Donating Members 4,243 Member For: 18y 5m 16d Gender: Male Location: Melbourne, VIC Posted 30/09/11 01:57 PM Share Posted 30/09/11 01:57 PM If your car is lowered, I feel sorry for your cold side pipes on driveways, dips in the road etc...You can get decent direct replacement coolers for the amount you have spent, an F6 cooler, Monza, Capa, possibly even a second hand PW stage 1 or plazmaman.. All a lot easier and can handle 300rwkw'sGood onya for having a crack though.. Link to comment Share on other sites More sharing options...
Garrettba03 Member 78 Member For: 13y 7m 21d Gender: Male Location: Sydney West Posted 30/09/11 02:16 PM Author Share Posted 30/09/11 02:16 PM (edited) Yeah I thought about all of those but the volume and size of this one is much bigger than all of those coolers. The core of the monza has very little turbulators, as soon as I find a good second hand deal I can afford...it was already sold.I was waiting for aages and really didnt want to keep waiting for ever, and I like getting my hands a lil dirty :-)I can now justify changing the valvesprings cause of what little I spent here. My last car swallowed $15k mods and dont wanna go there again.Cheers for that I usually always have a crack...occasionally I stuff things lol...but its rarely! Edited 30/09/11 02:18 PM by Garrettba03 1 Link to comment Share on other sites More sharing options...
Dillz Three pedals are better then two.. Donating Members 15,637 Member For: 17y 8m 11d Gender: Male Location: Melbourne Posted 30/09/11 02:37 PM Share Posted 30/09/11 02:37 PM On a second thought, bars look really thick and coupled with average end tanks, gains could be marginal. Link to comment Share on other sites More sharing options...
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