Editing Intercooler Mounting (section)

=drifda's mounting=

OK, so I'm doing an RB30E+T conversion and I thought I'd start with the intercooler first.

The job took me pretty much a whole Saturday.


Tools & Materials:

MIG welder, drop saw, drill, 25 x 25mm square tube steel, 50mm x 3mm flat plate


Start by placing the car on 4 stands nice and level. As you can see I ran out of stands so I did the dodgy thing and used 2 rims..

Remove the grill, filler panel (piece between the bumper and grill), front bar cover leaving the reo in place and head lights if you have aircon because you will need to move the A/C filter to the right and bend the alloy pipe a little as you can see in the pic.


[[Image:IntercoolerFit001.jpg]]


Prop up the intercooler with something, bessor block and a piece of wood??  Hey, it worked well for me...

Take your piece of square steel tube and cut it to about 820mm long, which was approximately 12mm less than the distance between the reo brackets.


[[Image:IntercoolerFit002.jpg]]


Also cut the ends just a little angled to suit the bumper bar brackets as they get wider closer to the bar... if that makes sense.


[[Image:IntercoolerFit003.jpg]] 


Then cut 2 small plates from the 50mm flat bar about 40mm wide and bolt them to the top of the cooler


[[Image:IntercoolerFit004.jpg]]


Now cut 2 more plates 100mm long for the end plates of the top bracket


[[Image:IntercoolerFit005.jpg]]


There are a couple of extra holes in the bumper bar brackets that are threaded which will be great for mounting the cooler bracket to


[[Image:IntercoolerFit006.jpg]]


Centralise the tube on top of the cooler and tack-weld the top mounting plates in place followed by the side plates. It should look like this:


[[Image:IntercoolerFit007.jpg]]


Mark and drill holes in the end plates for mounting. Handy tip! Screw a bolt in from the other side so that the end of it pokes through the hole and leaves a mark on the plate then just drill the hole and it will be in the perfect place...


I kind of ran out of materials for the bottom mountings so I just used some 5mm rod, welded some small plates to the end of them and screwed them to the bottom support panel with some large hex headed self tapping screws.


[[Image:IntercoolerFit008.jpg]]


Then you need to cut the back of the bar so it doesn't foul on the cooler, I chose to cut off the whole bottom lip because mine was already half snapped off. This is how it looks finished.


[[Image:IntercoolerFit009.jpg]]



[[Category:Engine]]