hey all i am fitting a isuzu npr large intercooler into the front of my car. what i want to know is who all has cut or modifying the opening to get more air in there. also theres like a front end support bar or something right where i want a bigger hole/extend up more. if anyone has any pictures or ideas that would be greatly appreciated. i have attached a picture of the front end from the inside. what i was wanting to do is cut a slit in the bumper where the molding comes around along the front. my problem is that big ole black bar in there. i know that it has a reason and what not but what is it? can i remove it or can i cut a hole in it? what have yahll done?

 

What is the area of your NPR intercooler core? The stock S5 front end will support up to about 348 square inches.

 

well where i plan on putting it the entire top half of the intercooler will be blocked off from getting any airflow. so i was gonna cut a hole in there to give it some air going to all of it. the core is 14.5 x 19.5 x 2 inches. i want to put it right in the front, basically right in front of where the power steering cooler lines are.

 

14.5x19.5 = 282.75 sq in

If you really want to cut up the front end, I remember somebody on this forum did that to their 2Gen, but I forgot who. I think they just cut downward from the stock inlet. Hopefully they will respond to this post.

 

thanx for the info. ill keep looking.

 

I cut down. gained around 1.5". you'll need a lip or soemthing though as well otherwise it'll look like crap. you can't go up unless you remove the main bumper metal surport (like 1fastT2)

 

Removing structural elements of your car just to get a little more cooling is not a clever thing to do.

Do what Scott did. That's the smart way.

 

No ****. You'll be sorry when you get into a front end collision.

 

youll be sorry if you get into afront end colloision no matter what. the peice of **** front bumper support helps a l ittle but doesnt help u all that much. Just plan on not getting into accidents. Heres mine, but this was just temporary, me and my friend were messing around and did this. I have an s5 bumper in the mail and the cars just waiting for some paint so its the temp toy. btw its not mounted just put on and my hoods not aligned lol here.

Done by butterfly knife and file.

 

Also consider the outlet path.
For example outlet louvers in the hood, behind the radiator (in place of the old inlet scoop.)

 

did you remove you front bumper supports inside and the foam??