Front mount intercooler fitted to a 93 Legacy turbo
13 March 2006, 10:02 AM
#1
Front mount intercooler fitted to a 93 Legacy turbo
I've been rather busy after the last 2 and a bit weeks doing this 
to line up where the pipe would end up going through the inner wing I used a piece of drainpipe cut to length
as well as lining it up the other side
It soon became clear that the intercooler needed to sit further back in the chassis to clear the bumper and I hed to somehow secure the bottom of the intercooler so I made these brackets with the help of V5 man (Cliff)
we then marked out the hole (Swiss Tony and myself) and then drilled small holes around the edge of the hole. This was the cut out using a junior hacksaw blade by Chris (Swiss Tony) and then smoothed off with a dremel This produced a hole like this.
I then filed the hole out, primed and painted it and then trimmed it using some rubber from the door shut off of another car.
back on with the wing
I then had to pipe up the other side of the intercooler.
It then ran!
Next up was the bumper
That took hours of cutting mostly by hand to get the intercooler and pipework to clear the bottom of the bumper. A Legacy bumper doesn't go straight down like an Impreza one
After I had the bumper in the right shape I gave the top of it a quick spray to get rid of some marks until the weather gets better and I can give the bumper a decent paint job and it was then onto the final straight and re-fitting it and the lights etc. This is what it now looks like
It just needs a number plate to finish it but I'm not sure what to do about that yet. Do I put a square on the passenger side over the foglight hole? my old one on the drivers side over the black part like the rally cars used to or what?
I'd like to thank everyone that helped me with this Chris & Cliff for their hard graft, Gossy for parts and STE.W and all of the other guys on the Legacy board for their pictures and advice
to line up where the pipe would end up going through the inner wing I used a piece of drainpipe cut to length
as well as lining it up the other side
It soon became clear that the intercooler needed to sit further back in the chassis to clear the bumper and I hed to somehow secure the bottom of the intercooler so I made these brackets with the help of V5 man (Cliff)
we then marked out the hole (Swiss Tony and myself) and then drilled small holes around the edge of the hole. This was the cut out using a junior hacksaw blade by Chris (Swiss Tony) and then smoothed off with a dremel
This produced a hole like this.I then filed the hole out, primed and painted it and then trimmed it using some rubber from the door shut off of another car.
back on with the wing
I then had to pipe up the other side of the intercooler.
It then ran!
Next up was the bumper
That took hours of cutting mostly by hand to get the intercooler and pipework to clear the bottom of the bumper. A Legacy bumper doesn't go straight down like an Impreza one After I had the bumper in the right shape I gave the top of it a quick spray to get rid of some marks until the weather gets better and I can give the bumper a decent paint job and it was then onto the final straight and re-fitting it and the lights etc. This is what it now looks like
It just needs a number plate to finish it but I'm not sure what to do about that yet. Do I put a square on the passenger side over the foglight hole? my old one on the drivers side over the black part like the rally cars used to or what?
I'd like to thank everyone that helped me with this
Chris & Cliff for their hard graft, Gossy for parts and STE.W and all of the other guys on the Legacy board for their pictures and advice
I am knackered after the hours I've put into doing that over the last couple of weeks 
13 March 2006, 11:53 AM
#6
Thanks Lee I wanted the hole to look like it'd been there since it left the factory so I spent so long lining it up I think it was 90% luck that we got it spot on first time with no adjustment needed 
I think I need to get some photoshops done of numberplates to decide what's best
I wanted the hole to look like it'd been there since it left the factory so I spent so long lining it up I think it was 90% luck that we got it spot on first time with no adjustment needed I think I need to get some photoshops done of numberplates to decide what's best
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13 March 2006, 12:46 PM
#8
Originally Posted by kilo_4que
I was very sceptical of the bumper clearing the intercooler but you got it done in the end.
It took hours getting it right and I ended up cutting my hands to pieces trying to just get the bumper skin to fit
cheeky barsteward 
13 March 2006, 02:16 PM
#14
Originally Posted by Silver Scooby Sport
The square one get's my vote
Paul is the existing bumper structural on the beam where the old plate was fitted ?
I'm curious to see if you could cut that out to expose the core fully hard to tell from the pictures.
Paul is the existing bumper structural on the beam where the old plate was fitted ?
I'm curious to see if you could cut that out to expose the core fully
hard to tell from the pictures.I could easily cut more out but I think I'd make a mess of it
13 March 2006, 02:41 PM
#16
Originally Posted by Silver Scooby Sport
Yes I see what you mean looking at them again 
You've got to know when to stop with the jigsaw
You've got to know when to stop with the jigsaw
It wasn't heavy to start with (which is why it needed respraying 
) but that's another story I was worried about it breaking because of how easily it twists once it's off of the car.
13 March 2006, 03:38 PM
#17
well I think it is a top job there mr palmer...
and although I concur with cliff's suggestion that you get out more or get a hobby, you cant fault your attention to detail (read **** ), nor your ability to put your hand to such a task.
I think you must get a big thumbs up just for tackling the job in the first place and the little touch's like the wing rubber sleeve, is just pure genious !!
I can post up the pics of my suggestions on the plate and mesh if you want, to see other ppl's opinions...but saying that..what the hell do they know
oh by the way, you forgot to post up one last picture, the photo of your new sponser
and although I concur with cliff's suggestion that you get out more or get a hobby
, you cant fault your attention to detail (read **** ), nor your ability to put your hand to such a task.I think you must get a big thumbs up just for tackling the job in the first place and the little touch's like the wing rubber sleeve, is just pure genious !!
I can post up the pics of my suggestions on the plate and mesh if you want, to see other ppl's opinions...but saying that..what the hell do they know
oh by the way, you forgot to post up one last picture, the photo of your new sponser
13 March 2006, 03:42 PM
#18
Originally Posted by SwissTony
well I think it is a top job there mr palmer...
and although I concur with cliff's suggestion that you get out more or get a hobby, you cant fault your attention to detail (read **** ), nor your ability to put your hand to such a task.
I think you must get a big thumbs up just for tackling the job in the first place and the little touch's like the wing rubber sleeve, is just pure genious !!
I can post up the pics of my suggestions on the plate and mesh if you want, to see other ppl's opinions...but saying that..what the hell do they know
oh by the way, you forgot to post up one last picture, the photo of your new sponser
and although I concur with cliff's suggestion that you get out more or get a hobby
, you cant fault your attention to detail (read **** ), nor your ability to put your hand to such a task.I think you must get a big thumbs up just for tackling the job in the first place and the little touch's like the wing rubber sleeve, is just pure genious !!
I can post up the pics of my suggestions on the plate and mesh if you want, to see other ppl's opinions...but saying that..what the hell do they know
oh by the way, you forgot to post up one last picture, the photo of your new sponser
Post up your pictures if you like
I really like them and I'd like to get peoples opinions so that I can a number plate on there asap instead of in the windscreen like I'll have to at the moment
The decision being based upon the fact that the sponsors logo clashs with his gay pink grill badge
13 March 2006, 04:27 PM
#23
ok paul needs your opinions (not on sponsership ) but on the placement of number plates, what kind of numberplate and also the possibility of meshing the FMIC later on this year.
so below (as well as MASS's contribution) are some options for you to choose from.
Option1: EVO style
Option 2: Diddy plate (get pulled by coppers a possibility)
Option 3: normal style plate, but slimmer and still legal size lettering
Option 4: meshing
option 5: mesh and evo plate
and any other you want to chuck in
) but on the placement of number plates, what kind of numberplate and also the possibility of meshing the FMIC later on this year.so below (as well as MASS's contribution) are some options for you to choose from.
Option1: EVO style
Option 2: Diddy plate (get pulled by coppers a possibility)
Option 3: normal style plate, but slimmer and still legal size lettering
Option 4: meshing
option 5: mesh and evo plate
and any other you want to chuck in
13 March 2006, 05:54 PM
#25
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Top job, I'd go for the Evo look and no mesh, but then I'm biased.
One thing I'd also do is change the blue hose's either side of the intercooler for black ones, the blue looks a little funny against the dark paintwork.
One thing I'd also do is change the blue hose's either side of the intercooler for black ones, the blue looks a little funny against the dark paintwork.
