Started upgrading my intercooler today and took some photos while I was at it.

Am upgrading a standard 95 WRX slanty IC to a 97/98 WRX IC I got from lightwave693, cheers again buddy.

ANyhow this is what i started with


This are the two IC's compared (bottom is the slanty)


The bracket in the centre of this picture stops the intercooler fitting correctly because of the y pipe, so it had to be modified. I cut and grinded it with an angle grinder and then painted it to stop it rusting and make it look a bit better.

Cut and ready to paint

Painted and earth lead re-attached


Thats all the cutting and gringing donw on the car now some on the IC itself, the connection to the throttle body needed trimming and the dump valve pipe needed to be removed.


Then a trial fit, all goes in well but I now need to get the DV hole welded, so will have toi wait till thats done to complete the fitting. Will update this once its all welded.



Ok so the welding of the DV hole is done, time for some etching primer over the bare ally


Then a quick blast of high temp mat black paint (after a thorough de-grease)


Finsihed product ready to be bolted in.


Ok so got it fitted in today, needed to remove the lafte hand brackets from the car to get it in, also had to chop the Throttle body But hey, it in and working fine.. Took it out for a spin, let it warm up and had a bit of a blast.. hit fuel cut once or twice so am going to just reset the ecu and pootle about in it for a week or so see how she behaves.




Comments as usual would be welcomed. CHeers



Cheers

 

looking good so far m8

how does the y pipe line up with the turbo outlet? do you have anyware to get the hole welded up? if you get a bit stuck, im a welder

Rich

 

It seems to line up fine with the turbo outlet.. although it may require some abuse to get back on.. Im dropping it off to a mates tonight along with a kawasaki engine to have some tig welding done on it. Not sure when I will get it back, but thanks for the offer

Have popped the old one back on for a few days as the brake servo in my landy has gone completely so its getting a bit interesting to drive, although I brought it to work today as im doing the beer run

 

Had it welded, so updated the pics, looks great Well i think so anyhow

 

Another way of doing the same thing I've done is to cut the excess length from the throttle body rather than the IC and use an IC from a 95-96 JDM TT Legacy (has no BOV pipe).

 

looking really good mate hopefully will stop raining to get it fitted. have you modified the undertray to suit the new cooler or make up a new one.... im planning on making a new undertray over the next week to fit my intercooler out of ally as mine is still a bit small.

Rich

 

Works do last night.. not ventured outside yet as im a bit shafted lol

I went to the scrappy to look for an under bonnet tray but they only had a scooby that suffered a unde rbonnet fire, nightmare. Managed to pick up a door for my little pug 106 in the right colour though.

Will probably make do till i find a scooby in the scrapper or may modify the original with some sheet ally i have banging about.

Going to have a crack at fitting it tommorow as long as its not belting down.

 

Make sure you get decent pipework under there, and dremel out the ally elbows smooth, that pipwork is very restrictive!

Simon

 

All in.. now i need to find an under tray and finish some brackets.. But basically its in and ready for a bit of fun.

As usual comments welcome, thanks to lightwave for the IC and everyone else that helped for their advise..

Cheers

 

good job looks like its made for living there hehe. have you got a boost gauge fitted? if not it would be a very good idea just to see what its hitting if your getting fuel cut.

take it easy until you get the undertray sorted as it wont be working at 100% until air is getting forced through the core.

good job

Rich

 

Yeah now in the market for a boost gauge.. maybe a manual boost controller.. wating on some advice from another thread

 

looks good m8,

dont forget to move the clip on the hose that comes off the manifold with the bolt in the end.