Thread: what are my options? intercooler dont fit..

If you were in Sydney, I'd send you to a guy in Dee Why West who'd do the mod for you probably by tomorrow. There must be people up your way that are the same.

Originally Posted by blackapache

could i mount the air con in front of the cooler... i guess im really negating any gains from having a bigger cooler then..

Yes you could.
This is how they are in the Puma and D2.
Whether this solves your plumbing problem is another matter.

I went through the same thing a couple of years ago. Got it to fit but took a bit of thinking and making new brackets etc.
If you were in Melb you could come and have a look at what I did. I did take photos. I'll see if I can find them.
I'm glad I kept the air con

alright so here's what I've come up with,

if i drop the air con down about 20mm, the intercooler will still fit between the pipework. I'm going to have to replace the rigid ally pipe that feeds the unit with a flexible style air con rated hose. so still some modding needed there. on the plus side i am then still able to change the element later if ever needed as the hoses are modded not the unit itself...

(I probably should have checked the Sandvik site to see if there was a better suited replacement unit too...... oh well were too far gone now)

i need to extend the allisport mounting tabs 12mm to get it to rest in the mounting tabs correctly and i should still have room for the front grill etc without having to muck around with the nose cone... i may have to grind off the internal bottom part of the nose cone ( theres a recessed lip on the inside at the bottom that looks like it may contact the front of the cooler or be very close to it - there looks to be enough room to get the clearance with some minor grinding)

i have a local guy thats an aluminium welder tig mig 1st class etc and he said he'd do the tabs first thing tomorrow,

So i'll see him tomorrow, then fabricate some small tabs to drop the radiator height, im sure i have some stainless flat bar and ally flat bar laying around somewhere - (see pics) then i'll put the air con back in followed by the cooler.

I'll leave the plumbing for the air con alone till next week as i want to drill out the centre under the fan and add another drain as per the bilboboggles mod to alleviate the sloshing water, then i'll have the filter changed regassed etc etc. - bilbo if you happen to read this I sent you a PM about your mod asking for a picture

hopefully i can get it all done in time to:

A. Get back to work this week,

B. have it done before my new ECU and boost box arrive from Jose (UPS tracking said its here tomoro!)

fingers crossed guys everything has been checked and rechecked, measured mocked up and measured again.. but that murphy bloke is sure to show his face at some point. I'll try to take some more pics as i go and that way if anyone runs into similar trouble it may be of some help later on.

Originally Posted by bitdist

I went through the same thing a couple of years ago. Got it to fit but took a bit of thinking and making new brackets etc.
If you were in Melb you could come and have a look at what I did. I did take photos. I'll see if I can find them.
I'm glad I kept the air con

yeah i dont use it much but its nice to have for sure..

Hay, how lucky was it that your AC leaked all the gas because the seals where cracked before you took the the pipes off
But seriously, watching with intrest as I want to put a bigger inter cooler too

Originally Posted by landy

Hay, how lucky was it that your AC leaked all the gas because the seals where cracked before you took the the pipes off
But seriously, watching with intrest as I want to put a bigger inter cooler too

Nooooo there was plenty of pressure in there still...... i sprayed yellow gas everywhere...

Originally Posted by blackapache

Nooooo there was plenty of pressure in there still...... i sprayed yellow gas everywhere...

No you didn't, that would have been illegal!

Unless of course you were using hydrocarbon refrigerant, you can vent that to atmosphere anytime you want.!