Alright, so heres my parts list and costs of parts, I get an exceptionally good deal on parts because my cousin is the manager at one of the local auto parts store, ive gotten a minimum of 30% off on each part, so expect to pay a bit more. All parts are priced in CAD
2006 WRX Intercooler : Free with car
Hose to make the turbo inlet/outlet connector: $40
Silicone fitting to go from TB to IC: $10
Coolant hoses and clamps to relocate tank : $5
Scrap steel to flanges, y pipe, coolant res bracket : Free
Mr gasket high quality gasket paper : $5
To do it how i did, a welder is nessicary. Your also going to need a grinder, vice, basic wrenches, and pliers.
I did an AC delete at the same time i did my TMIC, so my coolant resovoir is where my AC pump used to be. Heres how i did my AC delete :
Drain the freon out of the system. You can take it to a shop to get it properly done, or just loosen a bolt on one of the lines going to the compressor (theres 2 lines). Turn on a good fan and go away for a good 20 minutes. Come back, when theres no hissing you can take the lines completly off. Be aware this is bad for the environment, so just go to a shop to get it drained.
With the freon gone, remove the 4 bolts holding the compressor onto engine, and voila, no more AC. Theres a thing that looks like a radiator, sitting in front of your rad, this is called a condensor. Theres a few bolts holding it onto the car, take out the grille to get at them. With those bolts gone, take the two bolts off that hold brackets (which rubber mount the rad to the car) off. Pull back the rad a bit and slide the condensor out. Voila, your AC is gone.
Now for your coolant res mount. First off drain your coolant (little wignut type thing on passenger side at bottom of rad, mine is plastic). Unbolt the res from the engine (4 bolts or so), and begin to make your bracket for the mount. I just made one flat bar, with two holes in it to mount it to your stock AC mount. Then i took another strip of steel, put one 90 degree bend in it, and twisted it, then did another 90 (on the other side). This allows you to use two of the stock mounting holes in the coolant res. Heres what my coolant res looks like, remounted.. almost like factory eh ? Make sure to extend your lines, i used barbed fittings and hose clamps. Keep in mind theres excess coolant on my res because i overflowed it, and forgot about it when taking pics :
Next thing i did, is repositioned a bunch of wires. I put them under the "dog bone". These wires HAVE to be moved or they will interfear with your y pipe and intercooler. Simply take the bolt out that mounts dogbone to engine, and tuck wires underneath. There are a few clips mounting the wires to the body. Also, before moving the wires, take off the ignitor (In center of engine compartment, little black box, mine says hitachi, we'll remount that later. Should look something like this :
Alright, then i remounted my ignitor to under where it used to be, beside the wishbone :
You also have to cut your clutch resovoir, i cut mine down approx. 2". Use a syringe to take the fluid out of your clutch res. At the bottom of the plastic cut that holds fluid for the res, there is a clamp. Remove the clamp, pull the plastic cup off, cut it down 1.5"-2" and put it back on, clamp it back, put the fluid back in and your done.
Also, you have to take the chimney off the turbo, and chimney inlet off as well. Theres a few bolts holding the chimney to the turbo. To get the inlet off the hood, remove the black heat protectant layer from the hood (remove big circle clips, look like big smarties, i used a flathead), and unbolt the metal piece (Bunch of phillips head screws hold it on)
Now for the "fun" and labour intensive process of fabbing your Y pipe, we'll discuss that in the next post.
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