Clear Intercooler Answer PLEASE

[audipotential]

Will an Overall Size of 28"X7"X2.5" fit behind a stock bumper?

[audipotential]

Bumperoo

[A4ringedONE8T]

haha hell no. My core (without endtanks) is 22 x 11.3 x 3 and is THE BIGGEST that will fit, and I cut the SHIT out of everything. Had to move the lines in and out of the AC condensor, cut part of the radiator subframe to fit the pipes, and also completely remove the rebar from the bumper. O yea, and no fogs! Looks like so ...

[audipotential]

haha hell no. My core (without endtanks) is 22 x 11.3 x 3 and is THE BIGGEST that will fit, and I cut the SHIT out of everything. Had to move the lines in and out of the AC condensor, cut part of the radiator subframe to fit the pipes, and also completely remove the rebar from the bumper. Looks like so ...

Hey shawn,
Notice that I said overall size...
So including end tanks.
So either way I should look for about a 20 inch length without the end tanks to be safe?

[audipotential]

To be precise...
http://cgi.ebay.com/ebaymotors/CXRac...mZ330229435151
This is the one Im talking about.

[F16HTON]

YOu may be able to make that one fit. My core is 20" (without endtanks) x 8" x 3.5"

[audipotential]

YOu may be able to make that one fit. My core is 20" (without endtanks) x 8" x 3.5"

lol 3.5? No trouble with 3.5???

[A4ringedONE8T]

Hey shawn,
Notice that I said overall size...
So including end tanks.
So either way I should look for about a 20 inch length without the end tanks to be safe?

For a "custom" intercooler, they are a bitch to make fit. The AC condensor on our cars suck! The fittings are completely retarded and in the way! All of the premade setups are designed around them but a off the shelf core like Garrett or Precision is just a standard core obviously not made with the modifications to clear those fittings. Look at the AC condensor line on the drivers side of my car, how far I had to bend it out of the way to make fit. I had to cut its support of the condensor on the bottom, then heat it up and bend it back out of the way. For the pass side, I had to do the same, heat it up, and bend it back so the core could sit flat against the condensor, otherwise, it would not clear the bumper and stick out another 3/4"

Heres the pieces Im talking about

[lorvar]

Audipotential, just a reminder that if decide to cut into any part of the frame or remove the rebar and you get into an accident, the insurance company will tell you to take a hike. Get one that will fit without cutting.

[A4ringedONE8T]

lol 3.5? No trouble with 3.5???

No, the width, as I said clearing the AC condensor fittings, is the main problem. With a 20" core, you have more room in the center (that puts the core also inbetween those fittings) and it will fit fine

[F16HTON]

Nope

[A4ringedONE8T]

Greg what core is that? And did you make the endtanks?

[audipotential]

No, the width, as I said clearing the AC condensor fittings, is the main problem. With a 20" core, you have more room in the center (that puts the core also inbetween those fittings) and it will fit fine

Great so i'll look for 20 inch core...just so theres no funny business what should the overall be max..26 or so?
And is 3.5 the thickest I should go or should will 3 be less problematic to fit?

[audipotential]

Nope

Looks great greg, thanks for the pics
Have any bumper off pics?

[A4ringedONE8T]

Great so i'll look for 20 inch core...just so theres no funny business what should the overall be max..26 or so?
And is 3.5 the thickest I should go or should will 3 be less problematic to fit?

What turbo are you running this with? I wouldnt run a 3 or 3.5" core unless your at least on a BT setup

[F16HTON]

Greg what core is that? And did you make the endtanks?

Garrett high density bar and plate. The endtanks were made but not by me.

[F16HTON]

Looks great greg, thanks for the pics
Have any bumper off pics?

Nope...the intercooler is now part of the bumper assembly, remove the bumper, the intercooler comes off too.

[audipotential]

What turbo are you running this with? I wouldnt run a 3 or 3.5" core unless your at least on a BT setup

K03

I dont intend to go BAT for a little while..

Either way an ebay kit probably wouldnt hold up on BAT

[audipotential]

Nope...the intercooler is now part of the bumper assembly, remove the bumper, the intercooler comes off too.

...Yeah i see that now... So you have it mounted to the bumper rather than backwards with a bracket like everyone else...

Looks good!

[F16HTON]

...Yeah i see that now... So you have it mounted to the bumper rather than backwards with a bracket like everyone else...

Looks good!

Correct, unlike most setups that are attached to the radiator core, no part of my intercooler touches the a/c condensor core.

[ComfortRacing]

actually, yes it will. i bought the same one from the same dealer on ebay. it does take some cutting (alot), and i had to remove my fog lights. i flipped it so it would follow the lines of the grille. i will post pics for you tonight when i get home. the good thing imo, is that it fills the whole space below behind the grille (well where the grill went before i had to remove it to make this fit. you really should buy an after market bumper if you want to use this ic though.it would save you alot of heartache in the long run.

[mike-2ptzero]

K03

I dont intend to go BAT for a little while..

Either way an ebay kit probably wouldnt hold up on BAT

If you plan on staying with the K03 for some time dont get anything larger then 2.5" thick if going with a 20-22 long core that is 7" tall.


If you have 28" room the 22" long core should work since the end tanks really only need to be 3" long.

[audipotential]

So then why is the above user saying he had to cut so much and lose his fogs?

[mike-2ptzero]

So then why is the above user saying he had to cut so much and lose his fogs?

Shawn is using a 3" core that is 11" tall, he also lost his fogs because of how he ran his pipes. No way he was going to keep the driverside fog light while trying to use a 3" pipe.


Both of the ER kits allow the fog lights to stay because of how the pipes are designed. The ER sport is exactly what you would want for a K03 or small BT setup, it uses a 18x6.5x3 (22x6.5x3 with end tanks) 351 cubic inch High Density Bar & Plate Construction Intercooler Core. here if you want to read more about the ER Sport

[audipotential]

I meant comfortracing actually

[mike-2ptzero]

I meant comfortracing actually

Same reason, the universal kits dont use IC pipes designed for the A4 which means they dont fit exactly right. You get what you pay for when buying from Ebay, its that simple. It is just better to buy something that is designed for the car if you want it to fit perfectly.


When buying a FMIC you always want to match its size(volume) to the turbo setup your running, because going to large will hurt performance.

[knightstick]

When buying a FMIC you always want to match its size(volume) to the turbo setup your running, because going to large will hurt performance.

what would you say is the optimal size (or size range) for a GTRS on an 034 exhaust mani?

[A4ringedONE8T]

what would you say is the optimal size (or size range) for a GTRS on an 034 exhaust mani?

ER Sport will work, ER Comp I would say is best

[knightstick]

ER Sport will work, ER Comp I would say is best

i'll have a look again at the sizes they use but i plan to build a custom unit, so was more interested in what you guys think would be the optimum core size/volume

[A4ringedONE8T]

i'll have a look again at the sizes they use but i plan to build a custom unit, so was more interested in what you guys think would be the optimum core size/volume

Comp is 20x11x3, Sport is 20x7x3 IIRC, Mike can verify those. And regarding building a custom FMIC, just buy one thats premade, I wanted something very specific for my car hence the reason I built my own, endtanks and all, but it was a pain in the ass and cost more than even an ER Comp by the time I was done. Unless your pushing or going for 400whp+, the Comp is the way to go!

[ComfortRacing]

true, how you run your pipes has alot to do with it. the problem side is always the throttle body side. you have to A) miss the bumper support and large hex head bolt and B) dip down enough to miss the fog light assembly, which btw is frikken huge! i didnt buy a DIY kit (persay) i actualy bought mandrel bent 180 degree piping from summit racing and cut and welded them together for the lease amount of elbows and total length to cut down on friction loss which equates to pressure drop. some guys will also make the outlet piping from the turbo to the ic small like 2" which increases velocity and then on the outlet increase it to 2-1/2 all the way up to the tb. just my opinion.

[ComfortRacing]

also in the end yes i wish i had just bought the kit already designed, but being a Engineer i love the challenge of making my own and making it better. sometimes it pays off and sometimes it does not. i ended up spending what i would have for a premade kit, by having to continually redo my piping and clamps. somewhere there is a moral to the story i guess.

[A4ringedONE8T]

You will spend at least 450-500 bucks on a correct core (not an Ebay POS) without endtanks. Making a FMIC for anything under 400whp like I said doesnt make sense unless your just bored (or anal) as hell

[knightstick]

Comp is 20x11x3, Sport is 20x7x3 IIRC, Mike can verify those. And regarding building a custom FMIC, just buy one thats premade, I wanted something very specific for my car hence the reason I built my own, endtanks and all, but it was a pain in the ass and cost more than even an ER Comp by the time I was done. Unless your pushing or going for 400whp+, the Comp is the way to go!

cool, thanks for the info! i've been down the custom, one-off road and know how it can take longer and sometimes cost more but i really like having top notch custom parts built specifically for my car. not to mention, i'm a Spearco Master Distrib and my fabricator is second to none

[mike-2ptzero]

cool, thanks for the info! i've been down the custom, one-off road and know how it can take longer and sometimes cost more but i really like having top notch custom parts built specifically for my car. not to mention, i'm a Spearco Master Distrib and my fabricator is second to none

Well it doesn't come any more "top notch" then the ER built fmic kits. Plus if you want it built exactly for your car all you would have to do is make some changes to the IC pipe that comes in their kits. This way you only end up spending time on the IC pipe instead of building the whole thing.

Comp is 20x11x3, Sport is 20x7x3 IIRC, Mike can verify those. And regarding building a custom FMIC, just buy one thats premade, I wanted something very specific for my car hence the reason I built my own, endtanks and all, but it was a pain in the ass and cost more than even an ER Comp by the time I was done. Unless your pushing or going for 400whp+, the Comp is the way to go!

Correct on the Comp core

Sport core = 18"x6.5"x3"

Nice part about the ER sport is that it is on the shelf and can be shipped out the same day it is ordered.

[F16HTON]

Didn't we just ship one out yesterday?

[[IX]]

i'll have a look again at the sizes they use but i plan to build a custom unit, so was more interested in what you guys think would be the optimum core size/volume

ER SPORT

[mike-2ptzero]

Didn't we just ship one out yesterday?

Went out thursday so the customer should already have it.

[F16HTON]

Damn, I should have flown home to deliver it.

[TurboQuattroPwr]

How high of a turbo can you run with the sport without having to go bigger?