For those that are interested, this is how I installed an Ebay intercooler on my 1999 Stage 3+ 9-3 to fit through the stock locations.
The kit is from Just Intercoolers.
Core Size: 22x7x2.5 inch
Overall size: 28x7x2.5 inch
Inlet and outlet sizes: 2.5 inch
2.5" Polished Aluminum Piping Kit
http://cgi.ebay.com/ebaymotors/ws/e...ame=STRK:MEWNX:IT&viewitem=&item=230267115727
HOT SIDE
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COLD SIDE
FINISHED
Before vs After
Parts Used
2 - 90 Degree silicone Tubes (Cut)
2 - 2 1/2" to 2 1/4" Metal Pipes
1 - 45 Degree Pipe (Cut)
2 - Stock Intercooler pipes
Steps - More will likely be added when I remember them
Impressions
My test run was short lived. I was impressed with what seemed like a slight improvement in the power of the car. However the most improved thing was the ability that the car could keep the power. Multiple long pulls and the car was not losing power. There is also a slight sound you can now hear.
Apparently, the constant increased power was too much for my engine to handle. With earlier problems with the car from the first owner, a changed head gasket (w/ lots of work) and a turbo later problems had seemed to have gone away. I had not dropped the sump . A silly choice on my part because it seems it had slowly depriving the engine of oil. A big bearing was toasted, and I'm lucky no other damage was found as of yet. The engine is now removed and in for a rebuild.
Future Plans
In the future i hope to change the stock intercooler pipes, as they seem to be on their way out. I also hope to bolt the intercooler down so it sits straight.
More pictures are available if people are interested...
The kit is from Just Intercoolers.
Core Size: 22x7x2.5 inch
Overall size: 28x7x2.5 inch
Inlet and outlet sizes: 2.5 inch
2.5" Polished Aluminum Piping Kit
http://cgi.ebay.com/ebaymotors/ws/e...ame=STRK:MEWNX:IT&viewitem=&item=230267115727
HOT SIDE
----
----
----
---
COLD SIDE
FINISHED
Before vs After
Parts Used
2 - 90 Degree silicone Tubes (Cut)
2 - 2 1/2" to 2 1/4" Metal Pipes
1 - 45 Degree Pipe (Cut)
2 - Stock Intercooler pipes
Steps - More will likely be added when I remember them
- Remove Front Bumper - Remove original Intercooler
- Cut 90 degree sillicone angles so they don't bend to reach stock locations. (Creates a tighter angle than 90 degrees)
- Grind down the screw lug on the top of the intercooler and move up the AC dryer.
- Cut the 45 degree pipe to sizes given above. (Both sides will need to be cut)
- Test fit the intercooler and piping - Intercooler should line up in the middle when the pipes are in place.
- Modify the stock intercooler pipes and/or other pipes to fit. Install.
- Re-install flaps around intercooler - custom make your own to fill the rest of the gaps. We used some rubber sheet which was reinforced with webbing for this.
Impressions
My test run was short lived. I was impressed with what seemed like a slight improvement in the power of the car. However the most improved thing was the ability that the car could keep the power. Multiple long pulls and the car was not losing power. There is also a slight sound you can now hear.
Apparently, the constant increased power was too much for my engine to handle. With earlier problems with the car from the first owner, a changed head gasket (w/ lots of work) and a turbo later problems had seemed to have gone away. I had not dropped the sump . A silly choice on my part because it seems it had slowly depriving the engine of oil. A big bearing was toasted, and I'm lucky no other damage was found as of yet. The engine is now removed and in for a rebuild.
Future Plans
In the future i hope to change the stock intercooler pipes, as they seem to be on their way out. I also hope to bolt the intercooler down so it sits straight.
More pictures are available if people are interested...