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forester intercooler
Posted: Sat Jun 24, 2006 12:10 am
by billc
Hi everyone. I wanted to share my latest project with the group because it worked out so well.I installed an intercooler from a forester xt onto my old sport sedan. It fits into the engine bay really nicely, it also sits directly under the scoop. I had to shorten the clutch m.c. but other than that and buying a couple of silicone hoses it was a fairly painless install. I had already had a couple of different intercoolers on it so all the other stuff had been done already(a.c hose under the dogbone.relocated ignitor etc.).This is the intercooler that comes on the 06 wrx and it is smaller than the old ones so I would think that these will become available as people upgrade to bigger intercoolers.I am really happy with the way it looks and performs.I wish I could post pictures but I am to stupid with the internet to figure it out.

Posted: Sat Jun 24, 2006 2:45 am
by vrg3
Awesome. This is with the stock turbo? Could you by any chance come up with a list of the hoses you had to use?
If you're having trouble posting the pictures up, you could email them to me (vikashgoel at gmail dot com) and I'll post them for you. I would really like to see them.
Posted: Sat Jun 24, 2006 7:47 am
by greg donovan
cool. ever since i saw that these were a bit smaller i have been wiating for people to start selling them.
how does it work with the coolant expansion tank?
you going to be at OFPR in late august?
Posted: Sun Jun 25, 2006 1:41 am
by billc
Not the stock turbo. It is a tdo4 from a usdm wrx.Coolant tank had been relocated already from other intercooler installs. I did have to fabricate a fitting for the b.o.v. outlet. After I did that I saw bacically the same thing for sale on e-bay cheap.
Vrg3 what resolution pictures work the best?I will take some pictures and send them to you.BillC.
Posted: Mon Jun 26, 2006 5:26 pm
by vrg3
Any resolution is fine; just send the best you have, I guess. I'll manipulate them as needed.
Posted: Wed Jun 28, 2006 3:55 pm
by vrg3
Posted: Wed Jun 28, 2006 3:58 pm
by vrg3
Neat stuff!
So that's a Samco silicone replacement for the stock y-pipe? Is that the same piece as for 02-05 WRX intercoolers?
What's the little black pipe attached to the Y-shaped hose?
Did you have to make or buy an adapter to attach the 19mm hose for the blowoff valve?
Be careful with how you've relocated the coolant tank. When I did that I had problems sometimes with the engine rocking on its mounts and pushing the radiator cap up into the hood. The pressure was enough to make it leak.
Posted: Thu Jun 29, 2006 12:05 am
by billc
That is indeed a samco hose for the y pipe, and it is a 02-05 wrx model. The black pipe is just a piece of exhuast pipe painted black.I dont remember the i.d-o.d. I made the adaptor for the b.o.v.
I saw something very similar on e-bay after i finished. They only wanted 10 bucks for it,so if I would have seen that first I probably would have went that route.I kept the program for theb.o.v. plate so i could make another if someone needed one. I know about the coolant tank.I had a jdm a/w i.c. on there before this one and I also had the ductwork under the scoop still on there and the tank would bounce off the ductwork. I removed the ductwork and lowered the tank a bit. Since then I havent seen any coolant on top of the tank. Thanks a million for helping me with the pictures.
BillC
Re: forester intercooler
Posted: Wed Jul 12, 2006 9:53 pm
by Dr.Outback
billc wrote: I had to shorten the clutch m.c. but other than that and buying a couple of silicone hoses it was a fairly painless install.
I've been waiting to do this mod for over a year. I just wanted someone to go first.
How did you "shorten" the clutch master cylinder?
Posted: Wed Jul 12, 2006 11:34 pm
by Adam West
This is great! Planning something similar in the coming months and stockpiling parts...
You wrote: Clip<I made the adaptor for the b.o.v.
I saw something very similar on e-bay after i finished.>
Could you post the link to that part on eBay?
Thanks again for sharing!
Posted: Fri Jul 14, 2006 2:06 am
by billc
I shortened the resevior with a bandsaw, but a hacksaw would work just fine. It is held on with hose clamp. I simply removed it,cut some off the bottom ,put it back on,and the bled the system.I have had no issues with the reduced fluid capacity and I drive the car 70+ miles a day. I also beat the crap out if the car.
As far as the bov adapter goes, go to ebay motors and type in
subaru turbo bov adapter and the piece should come up. BillC
Posted: Fri Jul 14, 2006 2:31 am
by IronMonkeyL255
I believe that piece is the one I bought for my '02 WRX i/c install......
Posted: Wed Jul 19, 2006 5:31 am
by Adam West
How did you decide to use the stock recirc. BOV vs. an aftermarket one? Was space the main issue? Has anyone moved the coolant tank to a completely new place to give room for the BOV - feasible? Worth it? Can the OEM BO system handle lots of boost and is the aftermarket BOV merely bling or personal taste, other issues(may be an entire other conversation...)? Thanks in advance for any insight, Adam
Posted: Wed Jul 19, 2006 5:45 am
by Adam West
Never mind. Just search BOVs and think I've got some reading to do...Not fancied much here I take it. Again, nice work... Cheers, A