*Write-up* Ebay SSautochome intercooler install
01-26-2006, 07:33 PM
#1
Senior Member
Thread Starter
Join Date: Jan 2006
Posts: 1,114
SSautochrome intercooler install into a 1984 GSL-SE
Preliminary information:
The intercooler(IC) core that will be fitted is a 24”Lx12”Hx3”W. All other intercooler cores of this size should fit. However endtank location can alter a few of the variables while installing. This write-up will specifically discuss the install of a SSautochrome IC.
I will break the install into three sections; passenger, driver and both. In theses sections I will discuss the modifications that need to be made in order to fit the desired intercooler.
My design is used on a 1984 GSL-SE with the stock radiator, supports and no A/C. Other years, models may have differences. I do not warrant anything that you do to your car. This mod is fairly risk free but please use safety and know that this is done at your own risk.
Passenger:
The passenger side is relatively easy to modify. There is an existing slot that can be altered. The only problem is that the slot is slightly too small for the inlet to be pushed though. Please see figure 3 for a better understanding of the location. When slotting this there are a couple things that need to be taken into consideration.
You want the intercooler to sit flush against the support.
You want to make sure that the hood will still close after the intercooler is installed.
So this means that you want to slot the hole down and back. You can achieve this either by using a hole saw, cutting wheel, dremel, or whatever you feel most comfortable with. I personally used a hole saw to start however it was difficult to get the cut started. I then later resorted to using a cutting wheel which worked great. Please see figure 4 for a representation of the work that needs to be completed.
Driver:
The driver’s side support is a little more complex. However by no means is it difficult. I made the support slip over the intercooler. Since the radiator support jogs toward the center of the car it is a clear obstruction to the IC. Cuts need to be made 1.25" from the front for the support towards the intercooler. And from the back the intercooler a cut need to be made 1.75". Continue this cut vertical until you are 1" from the top(measurement should be taken at the front of the car). The shape should be a rectangle to accommodate the IC. Please see figure 5 for a visual representation.
1" top
1.5" back
1.75" front
*Please note that the front is on direct relation of the car. Meaning that front would be furthest from the cab.*
Both:
There are supports that are near the front frame. These supports are used to hold up the FMOC. If you do not have a FMOC then you do not have to worry about this. Also I believe that there were models where the Oil cooler was attached to the bottom of the radiator. Relocation is easy; however custom supports have to be made. Use a little innovation. For example the rails that sit directly below the existing mounts will work wonderfully. When the holes have been cut these supports do not allow the intercooler drop into the correct place. Take a cutting wheel and slice them off perpendicular to the ground. Make sure that you do not cut into the other support. There is no need to cut off more than is needed. See figure 6
There are also other small mounts and studs that are in the supports. These are not too much of an issue however a 10mm wrench and a couple seconds will make it easier for you not to scratch you nicely polished IC.
Oil cooler mounting:
Since you cut away your oil cooler mounts you will need to fabricate new ones. This is not too difficult. The oil cooler mounts nicely along the frame rails.
Additional supports:
There are 4 points on the intercooler which allow for supports. I hignly reccomend that such precautions are taken. If you fab up custom mounts for the FMOC you can just easily tie them into that design.
You’re done:
Now you’re done. See figure 1 for a finished product. The intercooler in the pictures is not the finished product. Since there was no intercooler wirte up such as this trial and error trimming was done. All measurements in this write-up were taken from the finished product.
I linked the pictures to a website so that people in the future do not have to worry about not having pictures.
Pictures can be seen here:
http://photobucket.com/albums/e330/z-beater/?sc=1
[u]
Preliminary information:
The intercooler(IC) core that will be fitted is a 24”Lx12”Hx3”W. All other intercooler cores of this size should fit. However endtank location can alter a few of the variables while installing. This write-up will specifically discuss the install of a SSautochrome IC.
I will break the install into three sections; passenger, driver and both. In theses sections I will discuss the modifications that need to be made in order to fit the desired intercooler.
My design is used on a 1984 GSL-SE with the stock radiator, supports and no A/C. Other years, models may have differences. I do not warrant anything that you do to your car. This mod is fairly risk free but please use safety and know that this is done at your own risk.
Passenger:
The passenger side is relatively easy to modify. There is an existing slot that can be altered. The only problem is that the slot is slightly too small for the inlet to be pushed though. Please see figure 3 for a better understanding of the location. When slotting this there are a couple things that need to be taken into consideration.
You want the intercooler to sit flush against the support.
You want to make sure that the hood will still close after the intercooler is installed.
So this means that you want to slot the hole down and back. You can achieve this either by using a hole saw, cutting wheel, dremel, or whatever you feel most comfortable with. I personally used a hole saw to start however it was difficult to get the cut started. I then later resorted to using a cutting wheel which worked great. Please see figure 4 for a representation of the work that needs to be completed.
Driver:
The driver’s side support is a little more complex. However by no means is it difficult. I made the support slip over the intercooler. Since the radiator support jogs toward the center of the car it is a clear obstruction to the IC. Cuts need to be made 1.25" from the front for the support towards the intercooler. And from the back the intercooler a cut need to be made 1.75". Continue this cut vertical until you are 1" from the top(measurement should be taken at the front of the car). The shape should be a rectangle to accommodate the IC. Please see figure 5 for a visual representation.
1" top
1.5" back
1.75" front
*Please note that the front is on direct relation of the car. Meaning that front would be furthest from the cab.*
Both:
There are supports that are near the front frame. These supports are used to hold up the FMOC. If you do not have a FMOC then you do not have to worry about this. Also I believe that there were models where the Oil cooler was attached to the bottom of the radiator. Relocation is easy; however custom supports have to be made. Use a little innovation. For example the rails that sit directly below the existing mounts will work wonderfully. When the holes have been cut these supports do not allow the intercooler drop into the correct place. Take a cutting wheel and slice them off perpendicular to the ground. Make sure that you do not cut into the other support. There is no need to cut off more than is needed. See figure 6
There are also other small mounts and studs that are in the supports. These are not too much of an issue however a 10mm wrench and a couple seconds will make it easier for you not to scratch you nicely polished IC.
Oil cooler mounting:
Since you cut away your oil cooler mounts you will need to fabricate new ones. This is not too difficult. The oil cooler mounts nicely along the frame rails.
Additional supports:
There are 4 points on the intercooler which allow for supports. I hignly reccomend that such precautions are taken. If you fab up custom mounts for the FMOC you can just easily tie them into that design.
You’re done:
Now you’re done. See figure 1 for a finished product. The intercooler in the pictures is not the finished product. Since there was no intercooler wirte up such as this trial and error trimming was done. All measurements in this write-up were taken from the finished product.
I linked the pictures to a website so that people in the future do not have to worry about not having pictures.
Pictures can be seen here:
http://photobucket.com/albums/e330/z-beater/?sc=1
[u]
01-26-2006, 08:07 PM
#2
Senior Member
Join Date: May 2005
Location: Choctaw, OK
Posts: 178
Nice write-up! I only have one thing to mention...
'79-82 RX-7s used the short radiators with under-slung oil coolers. '83-85 12As used beehives. GSL-SE's used mounts that situated the oil cooler right in front of the lower portion of the radiator. I've been told by reputable sources that '84-85 non-SEs have the brackets even though they use beehives. You can see one of the mounts next to the wiring harness on the bottom right of this picture... http://photobucket.com/albums/e330/z-beate...ersideMount.jpg
I'm currently running an '82 short radiator and oil cooler in my half-bridge '83. When I swap the motor into my GSL-SE I'll be upgrading to a GSL-SE radiator with a stock GSL-SE oil cooler mounted in front.
But I'd really like to do a turbo motor with a big@$$ intercooler!
Also I believe that there were models where the Oil cooler was attached to the bottom of the radiator.
I'm currently running an '82 short radiator and oil cooler in my half-bridge '83. When I swap the motor into my GSL-SE I'll be upgrading to a GSL-SE radiator with a stock GSL-SE oil cooler mounted in front.
But I'd really like to do a turbo motor with a big@$$ intercooler!
01-26-2006, 08:15 PM
#3
Senior Member
Join Date: May 2005
Location: Choctaw, OK
Posts: 178
BTW, what are you doing to cool that beast? If you're mounting the intercooler so that it covers the entire front of your radiator you're going to need some serious cooling upgrades. I'd at least re-core the radiator with a 3-row and replace the clutch fan with a big electric fan (over 2000cfm).
01-27-2006, 06:42 PM
#5
Senior Member
Thread Starter
Join Date: Jan 2006
Posts: 1,114
I have to admit that I did a lot of searching on ebay and the forums. People were extremely happy with this IC. Large, cheap, good construction and most importantly functional. There was a guy that pressure tested the IC at 50PSI and if IIRC there was less than a 1psi drop over night.
01-29-2006, 03:46 PM
#6
Senior Member
Join Date: May 2005
Location: Choctaw, OK
Posts: 178
The main purpose of fans is to move air through the radiator when the car isn't in motion. I think you are going to need extra cooling capacity to remove heat, especially when running heavy boost. Passing extra air through the radiator won't work if there's not enough surface area to radiate the heat into the air before it's gone.
01-29-2006, 03:53 PM
#7
Senior Member
Thread Starter
Join Date: Jan 2006
Posts: 1,114
Originally Posted by BeaterRX7' post='797604' date='Jan 29 2006, 01:46 PM
The main purpose of fans is to move air through the radiator when the car isn't in motion. I think you are going to need extra cooling capacity to remove heat, especially when running heavy boost. Passing extra air through the radiator won't work if there's not enough surface area to radiate the heat into the air before it's gone.
Yes I agree. This setup has been used before with no issues but I am not sure if they had a similat setup.
I am going to go v-mount. All hardware is back out of the car and I am making custom mounts for the IC/Rad. I will post a pic when I am done.
Thread
Thread Starter
Forum
Replies
Last Post
Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)