Rustynutz

So Easter monday was one long but very happy day, with huge help from the dad, and the use of Kip's great guide found on this forum, my new front mounted intercooler has been fitted...Yay!!!!!!

It all went pretty smooth with only a few problems along the way. One of which was a corrosion problem on the bumper bar



Everywhere else was fine and i was pretty pleased with the condition of everything once we had stripped the car down. We added some strengthening bars into the bumper bar and treated with some hammerite. This is only a temp fix though until i get myself a new one

After stripping the bumper and O/S front wing we removed the old intercooler



We then test mounted the intercooler



We then had to expand the hole in the inner wing allowing the pipe to run through and finished it with some rubber protective edging



We then started routing the new upper pipe work, this proved pretty tight in some places but it would fit!!!!!

We found shifting the batter over and squishing the washer bottle slightly gave us a nice tight fit


We then moved onto the lower pipes. We found the one side was too tight against the radiator fan, so we switched this over to the over side, giving us all the room we needed

Before


After


Now we had all the pipes lined up we reconnected everything and jubilee clipped up all the new hoses



To add some stability we fabricated some support bars for the underside of the FMIC



We then had to trim down the bumper to allow it to fix over the FMIC, and a lot of bumper had to come off!!!

Before


And when it was all cut we re-attached everything, polished up and stood back and enjoyed what we had made!!



One very pleasent way to spend a bank holiday!!!

ScoobyDoo69

iTrader: (17)

What kit was this then? Good work, just get a front lip now

Rustynutz

i got it off ebay, was mega bargain, it just titled as extra large intercooler for impreza, so no name!!! It seems real good quality though, just as substantial and as well made as far more expensive, named kits i've seen.

Would love to get a front lip on there but the angle of my drive to garage leaves not much room under there already so will have to check good and proper first. If needs be i'll just move my garage!!!!

ScoobyDoo69

iTrader: (17)

To be honest mate, a front lip like an Sti 6 one, really wont be any lower than the intercooler !

Rustynutz

I guess i'll start looking then!!!

Claaarkio

iTrader: (1)

Proper job mate!!

So what did you do with the rad fan? just move it? How difficult was that?

Cheers

Dave

Claaarkio

iTrader: (1)

OOh also where did you get the rubber edging from?

cheers

Dave

Scoobyslammed

I'd also like to know how you've moved the rad fan... as I've just rammed my fmic pipe work between them... yes its tight but it doesn't seem to cause any problems...
Just looked at your pics again... is it because you haven't got A/C... you only have 1 rad fan hence moved it along the rad...?

scooby1979

good work mate getting mine fitted soon

Pete

Good job fella, can`t believe the rust though.....

Rustynutz

Yeah, there's no A/C so could just slide it along. The only issue was the wiring as the fan wouldn't turn on when connected to the 2nd connector, so just had to extend the wiring on the first connector

Rustynutz

it was just some rubber tubing we had kicking about which we just slit lengthways down one side. Any small rubber tubing would do it.