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My custom intercooler setup
Thread Starter
Joined: Oct 2005
Posts: 1,687
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From: Fairfax, Virginia
My custom intercooler setup I have been working on this intercooler for a little while now and I'm finally finished. Here is what I started out with:
Heres what it looks like after lots of cutting and welding:
Installed:
Bumper cut
As you can see, I made it adjustable up and down in case I need to lower it for more airflow. The welds aren't professional, but I try. I only had about 6 hours of practice with the aluminum welder before I went at it. I'll have my piping next week and I'll start making the up pipe to the throttle body.
Heres what it looks like after lots of cutting and welding:
Installed:
Bumper cut
As you can see, I made it adjustable up and down in case I need to lower it for more airflow. The welds aren't professional, but I try. I only had about 6 hours of practice with the aluminum welder before I went at it. I'll have my piping next week and I'll start making the up pipe to the throttle body.
Last edited by Ralls; Mar 1, 2008 at 02:08 AM.
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Thread Starter
Joined: Oct 2005
Posts: 1,687
Likes: 0
From: Fairfax, Virginia
Thanks guys. Yep I'm single turbo, which is why I did all that modifying. It would of only used half the intercooler if I didn't box it in. I really wanted the intercooler going straight to the throttle body instead of the other way everyone does from the side. And that was the only intercooler I could find that did that. I could of bought a custom one for $500-$800 but I spent $200 and did it myself 
I sure hope I don't have cooling issues. The IC is a few inches away from the airdam mounts, so it should still get airflow. I'm putting the bottom bumper piece on today and I'll post some more pictures.
I sure hope I don't have cooling issues. The IC is a few inches away from the airdam mounts, so it should still get airflow. I'm putting the bottom bumper piece on today and I'll post some more pictures.
Thread Starter
Joined: Oct 2005
Posts: 1,687
Likes: 0
From: Fairfax, Virginia
It's a good 3-4 inches above the airdam. I couldn't put it on the ground to get the ride height look cause my rear end is out. 9" going in
. It's a little lower than I was hoping, but we'll see what happens. At least it will get some good airflow since I can't cut the center of the bumper like you LS1 guys.
Good luck with the build. 
Thread Starter
Joined: Oct 2005
Posts: 1,687
Likes: 0
From: Fairfax, Virginia
Well I'm still waiting on my intercooler piping. They were out of black silicone couplers so they didn't send anything until I called them a week later 
.
In the mean time, I made a few things:
Xmember for the new 9inch. Still need to make brackets.
TIG Weld
Made a battery box. Only cost me 3 bucks
.In the mean time, I made a few things:
Xmember for the new 9inch. Still need to make brackets.
TIG Weld
Made a battery box. Only cost me 3 bucks
Thread Starter
Joined: Oct 2005
Posts: 1,687
Likes: 0
From: Fairfax, Virginia
Got my intercooler piping finished today.
Question, does anyone know the outside diameter of a Tial BOV? All I bought was the flange for now, and it seems like it's going to be pretty close to the radiator. I just need to know how wide they are to see if I'll hit.
Question, does anyone know the outside diameter of a Tial BOV? All I bought was the flange for now, and it seems like it's going to be pretty close to the radiator. I just need to know how wide they are to see if I'll hit.
I am not sure where you guys get your intercoolers but its no where near $500.00-$800.00 to do a custom intercooler like that or any custom setup for that matter. Just a lil bit over what you spent and professional done. Should have looked me up
looks good, just wonderign how youre radiator will like the loss of air flow, most people usually mount it in front of, or replace the front bumper support, instead of where you put it, to keep full airflow to the rad.