legacycentral bbs

I have an early WRX air-to-air intercooler from oz installed on my 92 USA model Legacy turbo sedan. It can be made to fit, but it was far from a direct drop-in. None of te mouting ears line up to anything. I installed aluminum diamond expanded metal over the face and back of mine, because the fin are as elicate as aluminum foil and there is lots of crap to rub against them. It sits at an angle as it does on the early WRX. You have to unbolt your ("dog bone"" engine locator and shove the AC line under it. I screwed up and one month later, my clutch actuator arm had eaten a hole through my AC line. That is a $300 mistake, but it gave me an opportunity to have a steel midsection installed in the AC hose. The plastic intake pipe is made for a bigger turbo that sits at a different angle than ours. You must adapt down to fit a USA turbo, using either good quality radiator hose or silicone hoses and "hump" hoses and aluminum tubing. I sawed off my WRX intake pipe about halfway underneath the intercooler and adapted hose to that. That joint can be problematic. Seal it with silicone sealer and put three sheet metal screws through the hose so that it can't scoot. let it dry two days before putting on the hose clamp. The intercooler will cover your clutch master cylinder reservour. Your igniter will have to be unbolted from the firewall and left hanging on the wiring harness. The intake on your throttle body and the outlet on the turbo are the same size. Lining those two pipes up is what dicates everything else about location. Have an industrual hose fitting shop make a connector fitting with a 3/4" barb fitting on it for your compressor bypass valve. Last, but not least... keep your stock turbo pipe and the necessary tools next to your spare tire, in case you spring a leak. It takes a week or two of testing to be sure you can count on your intercooler connections.

Love
Bill Robinson
92 USA Turbo Sedan 5-speed


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Thanks for that info!

--- In BC-BFLegacyWorks@y..., "William D. Robinson" <vultureboy@m...>
wrote:
> I have an early WRX air-to-air intercooler from oz installed on my
92 USA model Legacy turbo sedan. It can be made to fit, but it was
far from a direct drop-in. None of te mouting ears line up to
anything. I installed aluminum diamond expanded metal over the face
and back of mine, because the fin are as elicate as aluminum foil and
there is lots of crap to rub against them. It sits at an angle as it
does on the early WRX. You have to unbolt your ("dog bone"" engine
locator and shove the AC line under it. I screwed up and one month
later, my clutch actuator arm had eaten a hole through my AC line.
That is a $300 mistake, but it gave me an opportunity to have a steel
midsection installed in the AC hose. The plastic intake pipe is made
for a bigger turbo that sits at a different angle than ours. You
must adapt down to fit a USA turbo, using either good quality
radiator hose or silicone hoses and "hump" hoses and aluminum
tubing. I sawed off my WRX intake pipe about halfway underneath the
intercooler and adapted hose to that. That joint can be
problematic. Seal it with silicone sealer and put three sheet metal
screws through the hose so that it can't scoot. let it dry two days
before putting on the hose clamp. The intercooler will cover your
clutch master cylinder reservour. Your igniter will have to be
unbolted from the firewall and left hanging on the wiring harness.
The intake on your throttle body and the outlet on the turbo are the
same size. Lining those two pipes up is what dicates everything else
about location. Have an industrual hose fitting shop make a
connector fitting with a 3/4" barb fitting on it for your compressor
bypass valve. Last, but not least... keep your stock turbo pipe and
the necessary tools next to your spare tire, in case you spring a
leak. It takes a week or two of testing to be sure you can count on
your intercooler connections.
>
> Love
> Bill Robinson
> 92 USA Turbo Sedan 5-speed


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Just fyi... I just saw a really good picture of a newer WRX
intercooler setup on the Legacy forum on i-club (http://www.i-
club.com). It's under the topic

ne1 have any idea what this is?

near the bottom. I hope mine fits as well when I get around to
putting one in.

RonOtter
91 Turbo Legacy Sedan

--- In BC-BFLegacyWorks@y..., "William D. Robinson" <vultureboy@m...>
wrote:
> I have an early WRX air-to-air intercooler from oz installed on my
92 USA model Legacy turbo sedan. It can be made to fit, but it was
far from a direct drop-in. None of te mouting ears line up to
anything. I installed aluminum diamond expanded metal over the face
and back of mine, because the fin are as elicate as aluminum foil and
there is lots of crap to rub against them. It sits at an angle as it
does on the early WRX. You have to unbolt your ("dog bone"" engine
locator and shove the AC line under it. I screwed up and one month
later, my clutch actuator arm had eaten a hole through my AC line.
That is a $300 mistake, but it gave me an opportunity to have a steel
midsection installed in the AC hose. The plastic intake pipe is made
for a bigger turbo that sits at a different angle than ours. You
must adapt down to fit a USA turbo, using either good quality
radiator hose or silicone hoses and "hump" hoses and aluminum
tubing. I sawed off my WRX intake pipe about halfway underneath the
intercooler and adapted hose to that. That joint can be
problematic. Seal it with silicone sealer and put three sheet metal
screws through the hose so that it can't scoot. let it dry two days
before putting on the hose clamp. The intercooler will cover your
clutch master cylinder reservour. Your igniter will have to be
unbolted from the firewall and left hanging on the wiring harness.
The intake on your throttle body and the outlet on the turbo are the
same size. Lining those two pipes up is what dicates everything else
about location. Have an industrual hose fitting shop make a
connector fitting with a 3/4" barb fitting on it for your compressor
bypass valve. Last, but not least... keep your stock turbo pipe and
the necessary tools next to your spare tire, in case you spring a
leak. It takes a week or two of testing to be sure you can count on
your intercooler connections.
>
> Love
> Bill Robinson
> 92 USA Turbo Sedan 5-speed


------------------------ ---------------------~-~>
Make good on the promise you made at graduation to keep
in touch. Classmates.com has over 14 million registered
high school alumni--chances are you'll find your friends!
http://us.click.yahoo.com/l3joGB/DMUCAA ... /X7OVlB/TM
---------------------------------------------------------------------_->

To unsubscribe from this group, send an email to:
BC-BFLegacyWorks-unsubscribe@egroups.com