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Getting this thing to fit is anything but plug & play!!

The biggy issue I ran into yesterday was the A/C line. It has to go under the dogbone so you can have the clearance. I had used the n/a A/C line, which I felt might be too close to the down pipe if I angled it downward. So I had to discharge the a/c system (had to do it anyway to angle the n/a line downward) and swapped the turbo suction line in.

Then getting the samco hose to fit was a bitch. Now I need to make a rest for the intercooler so it sits on that, rather then the clutch resevoir and being held in place by the hoses.

Routing the coolant & pcv hoses will be interesting. I think I've got an idea how to do all that. I will be running a catch cant from the PCV line coming from the block. From looking at the lines coming from the valve covers, there doesn't appear to be any extensive amount of oil coming from them, so I will probably not bother plumbing them into the catch can.

I cut one of the tabs off of the AWIC and believe I can mount the coolant tank sidways with a fabricated bracket to keep it in place.

It takes a bit of time to just stare at things and see what will work, and what won't. A little swearing also helps.

Here's some pics of the setup mocked up. I unfortunately am going to be out of town this coming week & weekend, so I won't be able to work on it.

http://www.main.experiencetherave.com:8 ... es/td05/02

ceramic coating or wrapping the DP will resolve the problem with things being too close - and if it did happen to burn a hole through the resulting escaping refridgerant would be an excellent audiable indicator and also exhaust any fires.


So you bought that samco hose for how much? And you're going to have to wack an entire end off of it to get it to fit? That's almost nuts man!

The dp is ceramic coated already. I've already dealt with it how I see fit.

I don't recall the cost of the hose. I bought the hose to use, and help ease the already non-standard installation. If it alleviates me having to hunt down lots of misc. hoses, and multiple connection points, I don't care.

It's only money

As for the mount for it to rest on, are you planning to use some existing mounting point, or drill new holes?
I'm thinking the cruise control bracket could share it's bolts' spot. Or maybe something coming up from the pitch stopper?
It should be lightweight and allow enough movement considering the AWIC is attached to the engine. So maybe some sheet aluminum?

I was going to mount it to the spot where the ignitor used to sit. I'll obviously have to remount the ignitor, but I think that would be the easiest thing to do.

I've got the main configuration laid out....it's just taking care of all the details, which I think I've got semi-sorted out in my head.

You should not mount it to the body, as that is just putting extra stress on parts that dont need it.

I'm not going to mount the intercooler to the body. I am simply going to make a support that the back of the intercooler can rest on, and relieve some of the weight the hoses are supporting.

In response to the title of Josh's thread here....

Yes, yes it is!

But once it is in, it looks good and behaves nicely.

Now I just got to change things around so I can get my AC back in my car.

After being out of town, I finally was able to work on things again this weekend. I didn't get as much time as I wanted on saturday, but things are moving along I guess.

I have the bracket fabricated that will support the back of the intercooler. It turned out pretty good, and is decently beefy. I'm going to put some weatherstripping on the top of the bracket so there's not metal-to-metal contact. The weatherstripping said it's pliable up to 140 deg F. Hopefully it'll be alright.

I also made up a little bracket to bolt the coolant tank to one of the original locations. It's not super secure, but it works, and with the hoses on, should be more then adequate to keep things held down.

Now I'm just battling with all the damn hoses, and re-routing them. I think I've got all the coolant lines figured out, however the PCV hose coming from the driver's side valve cover is looking like it's going to be a pain because it runs right through where the turbo outlet hose goes.

I'd like to finish things up next weekend, but I think it's going to take a little more time because I'm having to fabricate brackets and run to the store for parts.

I may have to pull the turbo to put on the hose for the main crankcase PCV fitting....yuck.

Anyway, here's the pics
http://www.main.experiencetherave.com:8 ... es/td05/03

Bracket looks good, simple and sturdy.

Thanks!

...and I can keep the ignitor where it was originally located....one less thing to mess with.

Where did you get the "Offset Clutch MC Resevoir"?

Frank (Blackbart)

Got the brackets painted, offset clutch MC resevoir on, and hoses routed for the coolant tank.

I had to pull the turbo to put that damn hose on for the crankcase PCV line.

Looks like I also either have a leak in the AC system, or the fittings on my system are holding....it's just a slew of issues....grrr

http://www.main.experiencetherave.com:8 ... es/td05/04

Cool, where did you get the rubber strip on the mount?

Lowes,

It's this stuff
http://www.main.experiencetherave.com:8 ... P_6883.JPG

I just cut a strip off.

I'm still waiting to figure out the AC bullshit. I bought a new manifold and gauges which may or may not help, plus I bought some dye to see if there's a leak. Otherwise my vacuum pump may need new oil.

I wired up the pump today, and ran a mini test. It's just not flowing worth a shit. Those radiators are just too damn restrictive, but I don't know what else to do. My only other option is to put in a positive displacement pump. Even if it was 5gpm....it'd probably be more then what I'm getting now.

The pump I have is a high flow low head pump. So if there's a lot of head pressure, it's going to flow like shit.

I got the fittings I was looking for too, so I'll probably mess with the PCV stuff tomorrow, and maybe the AC stuff.

Today went much better then yesterday....
http://bbs.legacycentral.org/viewtopic.php?t=28077

I had to put all the hose on and bolt the throttle body on afterwards. Let's hope I don't have to take the damn thing apart any time soon.

I've got everything pretty much situated, including the PCV system. I need to do a few more things, but the main pieces are in.

Here's the pics from today
http://www.main.experiencetherave.com:8 ... s/td05/07/

You poor yanks

Well.....it's done!

I'm only getting about 7 psi of boost on the stock wastegate. I'm not sure if that's the way it's supposed to be or not. If so, I don't see why hooking up the stock boost solenoid wouldn't work. The ECU is just trying to maintain a setpoint, so it should be able to compensate for the different spring rate as long as it's below what the stock ECU is wanting to control to.

I'll probably leave it alone until I get through this first tank of gas, to let the turbo break in.

The pump is working, and does seem to be working better then initial tests, however I'm still not sure if it's going to be enough. I did a small drive around the block and the intercooler was warm to the touch. I'll have to take an extended drive, and with the AC on (after I get it charged up) to see if the intercooler is cool to the touch.

If not, I'll need a new pump, and/or new radiators.

I also learned what happens when you put too much redline water wetter in....it foams up. I had to suck water out of the intercooler, and put fresh water in to help dillute the mix.

Here's pics of everything completed.
http://www.main.experiencetherave.com:8 ... es/td05/08

Sweet.
Sucking out water? Is that just 'cause you wanted to remove a little, or is there no drain valve in the system?

Nope, no drain valve.

On the stock system, the drain valve is on the radiator.

hey man,
can you explain how that intercooler works and where you got it , or got it out of?I must be blind ,i can't seem to find it in any threads,.I have a 1991 ss and want to intercool it,but having a tough time deciding on fmic or sti tmic,and now this one you have.Any suggestions?

sorry found it here,http://bbs.legacycentral.org/viewtopic.php?t=27021,
but still looking for suggestions on what i should use,and what you got your intercooler from?

I bought it from a member on the board. Check the parts shed forum.

I almost would recommend going with something else.....the required work to get this setup to work, and work well is a lot.

so would you suggest a wrx tmic and y pipes.I've read some threads and they seem to be pretty straight foward.move a few things but other wise no as bad as your project.looks great by the way!!!great job!!