d22 intercooler

She will be going pretty good i hope....

Nice one mate, she's looking good.

Its gettin there slowly. cheers benny

Good to hear u got tge boost issue sorted.

Looks like it will be a good system with a scoop and fan.

Well done the bonnet scoop. Geez my cuttin skills arent too flash didnt realize there was bracing underneath as i cut it from the top still have to clean it up a bit and mount the fans so anyways if anybody was ever keen to run something similar bought everything off the bay bar and plate 450×140×65 core 2.5 inlet, outlet, 2× 2.5"sharp 180 degree bends,1× 2.5" wide 180 degree bend which i cut about a 100mm off to fit underneath the cooler and used that bit of 100mm to extend to the turbo inlet,i only used 500mm of metre length of aluminum tubing,9× 67-75 hose clamps plus 2 6" thermo fans which im in the process of doin when the hot weather f#$ks off

Ok so doing the micro intercooler install after a few years of having the intercooler finally decided to pull my finger out and get the rest of the stuff.

did anyone have any dramas with the intercooler hitting the heatter pipe that runs along the side of the motor and how did you get around this problem?.

Cheers BP90

I remember doing mine,
It is very tight, only a few mm clearance of heater pipes and same with a part of the top of the turbo setup.

Everything has to be alligned perfectly when tightening the mounts and hose clamps.

Yeah ive got all the hoses trimmed and worked out where its all got to sit. Although cant for the life of me get the 2inch ally pipe to fit into the 1.75 silicone hose.. tighter then a fishes arsehole.

Yeah its bloody tight. Need strong hands.
I remember letting it sit in a cup of boiling water for a while but then its hard to handle.
Maybe try a bit of detergent to lube it up.

ben85 said:

Yeah its bloody tight. Need strong hands.
I remember letting it sit in a cup of boiling water for a while but then its hard to handle.
Maybe try a bit of detergent to lube it up.

Click to expand...

Cheers for the help ben85

Geeez i duno whether its just cause its a different brand of silicone hose or the aluminium joiner is slightly bigger. But yeha ive tried heating the silicone in boiling soapy water, tried freezing aluminium joiner for a bit, tried vasolene, filed the edge of the aluminium joiner down to a bit of a champfered edge hoping that would help. And still nothing. So now trying to find some alternative. With no luck at the moment.

Bart

thinking of fitting up a bigger cooler, i have this one here, 450x230x65.

maybe match it up with a scoop from fairline fibreglass.

Had a quick look at where the i/c will sit today.
It will come up slightly at the front and a couple of inches at the rear.
Bonnet closes easily even with the old i/c still on and the scoop which drops an inch or more into the engine bay (the big scoop doesnt protrude into the engine bay at all) so it seems like theres plenty of room in there.
The hardest part will be making the brackets to set the i/c in the right position.

How the scoop will sit.

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That looks mint. I can't see but is there a fan under the IC?

Boogieboots said:

That looks mint. I can't see but is there a fan under the IC?

Click to expand...

No, but there will be twin 7" fans (switched in cab) on top when its all finished.

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Awesome. I am keen to see how this turns out then. I have been puzzling over how to fit a decent sized IC
and that looks like a pretty good setup.

Ahh. You have a body lift don't you Ben? Not likely to work for me I guess

Boogieboots said:

Awesome. I am keen to see how this turns out then. I have been puzzling over how to fit a decent sized IC
and that looks like a pretty good setup.

Click to expand...

Yes i have a BL.
I think you would struggle to fit it without a bodylift, however, i think there could be a chance...
If you leave the fans off you might be able to cut the hole in the bonnet just right so it allows the cooler to sit a bit higher, only issue would be the pipe work, but there might be just enough width in the scoop to cover if you cut out a bit for the pipes aswell.

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Slowly getting things done.

Bonnet from the wreckers, had the scoop painted and partially mock fitted.

Well its all done.
Don't think I will bother fitting a fan on top.
Would definitely be interesting to see temps pre and post intercooler, but i'm not keen enough to fit sensors.

I now have a top mount micro intercooler going cheap if anybody wants one.