Front mount intercooler? Oh ya.

[88FESTIVAGTR]

Well here it is. Sort of. I have just started it, only have about 6 hours or so so far. I should have it finished up by Monday or Tuesday, so check back here for updates. I am making the entire intake system out of 2 1/2"pipe. I had custom flanges built for the entire turbo. So I will also be building my own down pipe. 3" down pipe w/complete 3" exhaust. Of coarse I'll post pics.


crappy pic, I know, I'll get better, these were quickies. Basically this is the largest intercooler you can fit on a festiva and still keep the stock appearance. (the damn intercooler sticking out the grill or the bottom of the bumper! you know.) It is 9" high 28" long. I suppose you cold go longer, but you would have to pipe under or around the core support. This is packaged good.



Here is a pic of the FMS front bumper with that intercooler behind it. It did take some trimming to the air-dam. I plan on cutting the front air-dam bigger to allow more air. Once again crappy pic, but bare w/me. There's better to come.


Here is a little closer pic of the front mount and a basic look some of the modifications that have to be done to the bumper support. There is a lot of work to get this intercooler to fit. It is NOT a BOLT-IN deal. I'll get some detailed pics and a Small write up on this deal. But one thing to keep in mind is that the front bumper support is the only thing that holds together the frame rails, so it HAS to be rigid! You can't cut it out completely. I have welded all the seams, and boxed it in. Also intercooler pipe bends are very tight. I used 2 1/2" donuts from road race engineering.


Just another pic of the front bumper. Defiantly need a bigger air hole.

[stiva]

hell yeah dude thats bad ass

[mattswabb]

Looking good. Nice to see some updates on your project. When's the planned roll out date?

[EVOGUN]

Finally, you get some new pics man we all are waiting on you! Haha good work, keep it up you will never catch me at this rate .

Looks sexy, I didn't wanna be the only one with a monster I/C.

Thanks :wink:

[Safety Guy]

That looks like some really nice work.

Are you going to extend the air dam "rectangle hole" upwards or will you make some new holes in the upper/middle bumper?

Karl

[disableddan]

Looks sweet!! Does it have a motec system exhaust and a stand alone fuel management system? Because you know, it's not a bad way to spend $10,000!

Can't wait to see that thing move, I bet it's scary fast!

[88FESTIVAGTR]

Ya. move rectangle hole upwords. Worked on it about 4 hours last night. I'll get some pics tonight. I fabbed up the outlet of the intake side of the turbo. I still have to clean it up sand it down, seal the welds, and paint it. I'll get pics.

[stiva]

what I/C is it

if i went turbo i was thinkin about a Saab 900 turbo I/C

[88FESTIVAGTR]

This is a pic of how the intercooler sits flush. You can also see the mounting bolts on top of the bumper support.


kind of hard to see the plumbing here.

a little better here.





This is a little better. here you can see the basic layout of the pipe. It may not look like much. But it was hard. Well...at least for me it was.


another good pic. Here you can see the mounting tabs on top of the intercooler. Holes were actually cut inside the bumper support to recess these in to get the proper clearance. You can also see the silicone intercooler hump connector. My intercooler is mounted solid, and the motor has movement. The hump hose is to allow the movement.

here the pipe is on the motor. 2 1/2" pipe. Needs to be cleaned up and painted.


Oh here is the link to this intercooler. I bought it off e-bay. I have pretty much built this car off e-bay. Not a whole lot of people who cater for festiva's w/ a GTR motor.

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&rd=1,1&item=7973002893&sspagename=STRK%3AMEAFB%3AIT

[Rumnhammer]

ic

That's basically what I did, I made the hole in the bumper bigger, for future large front mount use. For the bumper support I totally cut out the center, then bolted it back up and welded in a top support beam. does the trick. I like the shot of your dog farting into the end of the intercooler at least that is what it looks like. :lol:
Chris Rummel

[Silv3rBull3t]

Looks awesome! Keep up the good work.. Most of the mechanical work looks to be done just the finishing touches! Keep us updated! -Kyle

[glacius182]

:notworthy:

[88FESTIVAGTR]

stupid dog. I have the other side of the pipe finished up today. I'll have pics tomorrow. It has been more work than I have anticipated. There is alot more work ahead of me also. I am undicided on how to finish the pipes. I will either paint them wrinkle red like my valve cover, or wrap them in exhaust wrap. After I paint them black of corse.

[JerseyJay1.8T]

Why would you wrap them in exhaust wrap? I mean, that's good for the few sections closest to the exhaust and the turbo, but compressing air makes it hotter, so wouldn't you want the pipes to be uninsulated so that even more heat escapes? Obviously the intercooler is doing the bulk of the work but there's no reason to insulate the piping with exhaust wrap and hold heat inside of them. Just curious.

[88FESTIVAGTR]

under hood temps would heat the metal intercooler pipe, the air inside the pipe is cooler than the air under the hood. It would be to keep the hot air from heating up the pipe. But any way, I have decided to paint them. Also didn't get around to taking more pics today, I'll have to do some tomorrow.