M2 Large Intercooler Duct won't fit w/Fluidyne radiator
#1
Senior Member
Thread Starter
Join Date: Apr 2001
Location: Charlotte, NC
Posts: 306
Likes: 0
Received 0 Likes
on
0 Posts
M2 Large Intercooler Duct won't fit w/Fluidyne radiator
I was installing my M2 Large intercooler last night and I found out that I can't get the duct to drop completely down in the opening in the front bumper. After some investigation i realized that the extra gerth of Fluidyne pushes the ducting up into the front bumper support. I am thinking about extending the cut out in the ducting further up into the neck so that I can get it to drop in but I am unsure of how to or if cutting into the fiberglass will damage it. Does anybody else have any solutions? I don't think I can slide the radiator down any more because it is sitting on the bump stops at the bottom and the brackets are bottomed out. How do you cut into fiberglass? I was going to tape the areas that I was going to cut into and then use a hacksaw. Any help would be greatly appreciated.
#2
Rotary Enthusiast
Join Date: Oct 2002
Location: fly over state
Posts: 806
Likes: 0
Received 0 Likes
on
0 Posts
I had to cut mine with a dremmel tool. Use some sort of highspeed rotary cutter as a hack saw or the like is more likely to shred the fiberglass. I made the cut so that the top of the intercooler leaned forward more to make more height clearance
#3
I solved this issue by
1) removing rubber bump stops, replaced them with a bolt and a couple rubber washers (lowered radiator almost 1/4")
2) ground out hanger brackets so they allow radiator to hang 1/4" lower
Sum total of nearly 1/2" drop for Koyo rad, now ASP large ic duct fits much better. Don't cut the ducting. There's no going back if you botch that...
1) removing rubber bump stops, replaced them with a bolt and a couple rubber washers (lowered radiator almost 1/4")
2) ground out hanger brackets so they allow radiator to hang 1/4" lower
Sum total of nearly 1/2" drop for Koyo rad, now ASP large ic duct fits much better. Don't cut the ducting. There's no going back if you botch that...
#4
I am having the same problem with my ASP SMIC. I have a fluidyne and have been working on this for a few days trying to get it to fit. Zullo seems to have an interesting idea. Any other help???? Please???
#5
Senior Member
Thread Starter
Join Date: Apr 2001
Location: Charlotte, NC
Posts: 306
Likes: 0
Received 0 Likes
on
0 Posts
I'm going to give that a try tonight when i get home to see if I can get that to to work. I would much rather remove something I can put back rather than cut into that pretty duct.
#7
Do it right, do it once
iTrader: (30)
I had to lower the AC condensor with ~ 1/4" spacers, remove the rubber mounting thingys at the top of the radiator and just bolt one side in to prevent the radiator from being stressed from body flex and thermal expansion (~.060").
Then I ground the duct in a couple of places (where the highest point of the fan motor is) just a little bit and it all fit fine.
Then I ground the duct in a couple of places (where the highest point of the fan motor is) just a little bit and it all fit fine.
Trending Topics
#8
Originally Posted by turbojeff
I had to lower the AC condensor with ~ 1/4" spacers, remove the rubber mounting thingys at the top of the radiator and just bolt one side in to prevent the radiator from being stressed from body flex and thermal expansion (~.060").
Then I ground the duct in a couple of places (where the highest point of the fan motor is) just a little bit and it all fit fine.
Then I ground the duct in a couple of places (where the highest point of the fan motor is) just a little bit and it all fit fine.
#10
Heh, forgot that detail about the A/C condensor since I'd removed mine. Yes, that will have to be lowered a bit (with spacers) to allow the radiator to hang lower.
By the way, here's where I earn my keep on this board with some good advice!
A month after you have the IC installed, remove the whole thing and check it for spots that are rubbing. I found the bottom of my IC would have had a hole worn in the aluminum (Eeeeek!) where it was rubbing on a bolt. I found the intake hard pipe to the elbow was similarly rubbing on a bolt (power steering pump I believe). Finally I noticed two spots on the fiberglass duct that would have worn through. One where it rests on the fans and the other where it was in contact with the A/C evaporator. I fixed/removed/reinforced all those spots and thought to myself, "I gotta remember to suggest this on the forum to save someone the unpleasant surprise of a hole worn in the bottom of their new $1500 intercooler"
By the way, here's where I earn my keep on this board with some good advice!
A month after you have the IC installed, remove the whole thing and check it for spots that are rubbing. I found the bottom of my IC would have had a hole worn in the aluminum (Eeeeek!) where it was rubbing on a bolt. I found the intake hard pipe to the elbow was similarly rubbing on a bolt (power steering pump I believe). Finally I noticed two spots on the fiberglass duct that would have worn through. One where it rests on the fans and the other where it was in contact with the A/C evaporator. I fixed/removed/reinforced all those spots and thought to myself, "I gotta remember to suggest this on the forum to save someone the unpleasant surprise of a hole worn in the bottom of their new $1500 intercooler"
#12
It worked!!
The lowering of the radiator by removing the top rubber mounting thingys worked. I lowered my A/C condensor also by installing washers (about a 1/4 inch @ each corner) to shim the condensor down further allowing the radiator to sit lower. Then at the top of the radiator i installed a rubber washer and a bolt on both the left and right hand corners. The intercooler duct slipped right in after that.
I cant believe that after all the searching i did i could not find any info about this on the board. This radiator is a Fluidyne also, not a Koyo which i thought would have been a little easier of an install.
Thanks for your advice Zullo and TurboJeff it helped out a lot.
I cant believe that after all the searching i did i could not find any info about this on the board. This radiator is a Fluidyne also, not a Koyo which i thought would have been a little easier of an install.
Thanks for your advice Zullo and TurboJeff it helped out a lot.
#13
Originally Posted by potatochobit
how close is the A/C condenser supposed to be to the radiator? its been so long i forgot.... if its too far away the fans cant pull air through the core right?