rob_yorky

Ive just bought a sti5 intercooler, has anyone fitted this to there uk pre-facelift car? if so can u tell me wheat i need to do to get it fitted etc.

also i guess i'll need a sti5 scoop undertray?

can i still use a dump valve?

[Davey]

You need to weld up the standard dump valve output and weld in a new one on the other side..

Heres one I made earlier so to speak:


Its been painted silver now and I've tidied up the fins

As you say you need the under plate or you can modify the original, or even just cut of the current slanted sealing part and use some thick adhesive foam instead...

Oh and you need to fabricate some brackets.

rob_yorky

thx for the info m8, hope u dont mind me asking but who, where did the welding and how much was it?

any more info on what/how to make the brackets?

heres a pic of the one ive bought -

[Davey]

My neighbour did the TIG welding on the intercooler (for a favour) and I've fabricated brackets from steel using a MIG..

The one you have is the same in dimension its just a silver STI one

willgill

iTrader: (1)

prepare to bleed

alot

this is an awesome guide, not entirely relevant but some good advice along the way
https://www.scoobynet.com/projects-40/515579-diy-sti-8-intercooler-onto-my00-classic.html

its a very very snug fit

rob_yorky

thx again for the info davey.

willgill - ive seen that already, been doing a bit of research but couldnt find much info about doing the mod with a pre-facelift and a sti5 intercooler so is any of that relevant as its a different intercooler and model of car thats been used compared to mine. i apreciate the thought though.

axgt_bwaii

iTrader: (6)

can you tig weld an alloy intercooler?

willgill

iTrader: (1)

I made a post years ago when I converted my MY95, it basically involves you bashing the crap out of you car and cutting lots of bits off

the hardest part I had was getting it to sit low enough, that involved cutting the Y shaped piece of metal just above the engine mount, certainly no for the faint hearted !! then it was wiggling the intercooler/throttle body hose into place with about 5mm to play with! its well worth doing for a number of reasons, it looks good, its functionally superior and it damn hard to do so when you manage it the reward is three fold

scoobykevuk

in the end will it make much of a defference???
#

willgill

iTrader: (1)

yep allows you to run more boost

[Davey]

I've encountered a small problem...

The throttle body on the later classics is shorter, ALOT shorter..

willgill

iTrader: (1)

shorter? that shouldnt be a problem, I had to trim mine down as the gap was so small, if you have lots of room to play with just order a longer Samco hose

[Davey]

If it comes down to it, I think I'll trim as much as possible of the i/c then attack the tb

willgill

iTrader: (1)

ahh I see what you mean, shorter in terms of cuttable metal I cut the I/C side down very low, I would have gussed at around 1cm of aluminium remaining. make sure you get dependable circlips I used three on mine in the end just to make sure it wasnt going anywhere

harvey

iTrader: (48)

Best advice would be to fit a front mount. It is a lot of work for limitted gains. You can use the STi5 BOV or use a commercially available adaptor plate and vent to atmosphere.
If you do it, you need the under plate from the STi 5. running without it will lead to higher under bonnet temperatures, quite noticably.

[Davey]

Dont worry the under-plate is the least of my concerns, got that covered

I thought the bugger was going to bolt right on, looked good when holding it over the original slanty I/C.. turns out its not such a good fit lol!