36 replies to this topic

[lookforjoe]

fischmama, on 19 December 2011 - 05:39 PM, said:

I think you are underestimating how much you will need to cut from the headerpanel with this setup. Unless you plan on adding fiberglass to it again to re-enforce it.

Or are you planning to mount it lower than me?

Hey Justus - It's probably not clear in the sketch - I'm assuming I will cut all but about 1" of the header panel - enough to leave a inverted "U" for some rigidity, and leave a little more dropping in the 'tab' areas. I need 4" above what I have now, which pretty much gives about an inch of the fibre header panel left.

[Ian Carr]

as did I. 99+ that appears to be souly a radiator support

[lookforjoe]

More like this....



.. looking at Justus's with the header panel in place, I may not be accounting enough for the curve of the nose - the ends of the IC will likely stick out more relative to the panel. I'm going to have to play that by ear once I have the IC & can make more accurate measurements. I want to retain enough of the header panel for it to be somewhat rigid, so maybe reinforcing the under side with aluminum & fibreglass will be the way to achieve that. I did pretty much that when I fitted the spoiler to the X19

[dublin14]

Are you using the WMI?

[lookforjoe]

No. Still need to get the correct fluid. WW Solv isn't cutting it - the mix is too diluted - 65/35 is a good as I've found.

Haven't found a local source for bulk quantities of Methanol, or whatever the other solvent is (can't remember offhand)

[lookforjoe]

Cut up a bumper bar yesterday & made a section to fit above the existing crossmember. I used the lower section as a guide to contour the "feet". I don't know until I remove the header & cut the crossmember exactly what the footprint of the member is where those will end up. I will likely have to cut one or other of the sides off & either butt it up against the back or front edge, depending on the positioning of the IC relative to the AC condensor & bumper.







I'll add gussets when I know for sure the width is OK. I'll have to add tabs for the header panel, as I believe the entire lower lip will have to go - I measure 4" from my IC to the top of the header lower lip -



- I need 4.5" for the IC to fit height wise...

[lookforjoe]

IC came today, so I took my parts to the machine shop & worked on the fabrication of the support. Since he is closed next week, I had him weld some extra tabs for me, incase I need them to secure the header panel. So, this way, I can cut up the stock crossmember, and adjust the aluminum mounting tabs to fit the crossmember on either side. I'll then silversolder some cative flange nuts to the sheet metal, so I can bolt this support to the crossmember outer sections as needed.

Had him weld extra bosses to the sides of the IC, so I can bolt in 4 spots for greater rigidity.





front corners



back corners

[lookforjoe]

Realized as I was sitting looking this over - that the measurement for the upper section of the IC (the additional 4.5" over my existing) was based on measuring from the crease line in the crossmember - I made the side supports 4.5" from the top of the crossmember

So, I made some 2" spacers, drill & tapped the support plate, & cut plates to go on top of the crossmember: basically, the support plates on either side will be cut to fit inside the cut crossmember, at the crease line, instead of on top. The spacers will offset the support bracket downwards the 2" I need to have the lower section align properly with the existing IC piping, etc.







like this:

[BlackT5]

With that end tank design, is the upper part of the IC really going to be utilized? I realize that it is more of a thickness issue in your case, otherwise I would have suggested using something like the 600HP Precision IC i'm using.

[lookforjoe]

BlackT5, on 24 December 2011 - 01:39 AM, said:

With that end tank design, is the upper part of the IC really going to be utilized? I realize that it is more of a thickness issue in your case, otherwise I would have suggested using something like the 600HP Precision IC i'm using.

Sure it will - I believe when you have a pressurized system it will fill no matter what - given a suitably flowing turbo compressor. The pressure drop across the IC is only .5psi under 15psi boost, not really any different than what I have now. This one can handle significantly greater flow than the current one, should help keep IAT's down in the upper rpm's..

Yours is 31x8x3.5, which has the same core width of 24", so that's only 2" wide than the one I have now, same height & depth...

[fastwagonhawaii]

I wish I had your welding skills. that looks good.

[lookforjoe]

fastwagonhawaii, on 24 December 2011 - 10:17 PM, said:

I wish I had your welding skills. that looks good.

So do I - I had the local machine shop owner weld for me - he has a nice TIG

Did another drawing to figure out the measurements.....



...but I misjudged the thickness & amount of room on either side of where I needed to cut..





not enough room for the extended bracket I made, has to be more like this



so, I cut out the 28" needed to fit the support brace & the bottom of the header panel



cut down the ends of the support



redrilled for a single support spacer sleeve to offset the support down the needed 2"



side reinforcement



the support brace had to be flexed to fit inside the frame section, so it's a nice snug fit.



right side



left side



RAD AC IC Sandwich




Cut header panel, this width IC requires wiper delete, with the support I made, anyway...



right side



left side



put a plate behind & bolted the center support to the IC brace



Hood wouldn't latch - the center was lifting somewhat - I had to trim the center & sides where they were pressing on the IC support

[fastwagonhawaii]

Your work is always so damn clean. love it

[andyb5]

That IC is huge! Great job on on the install, just as well-executed as the rest of your work.

[fastwagonhawaii]

just curious, are you going to modification to the bumper cover at all?

[lookforjoe]

^ Thanks, guys!

@fwh... I already enlarged the center opening - I'm not sure I can cut anymore out & still have it look OK.
pic from the Fall....


I may play around with another front cover, just to see what I can come up with.

['12brotruckmofo]

Awesome intercooler install. I avoided this thread because I thought it was about your old intercooler and the accompanying modifications...but this is so much cooler! Excellent work as always.