SW - DUBS How To Page
Front Mounted Intercooler Fitting
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This is a guide for fitting a 'pro alloy' front mounted intercooler kit (£560+vat) from www.proalloy.co.uk written by Olly Elworthy from the swdubs forum (cheers mate).
As with all the guides on this site swdubs.co.uk accept no responsibility for any of the information contained within this document or the accuracy thereof. It is intended as a helpful guide and is solely based on personal experience. The authors also wish to stress that the methods highlighted are centred around personal opinion and there may be other equally credible ways of performing this conversion.
The intercooler kit used in the guide is only one of many available on the market today, and is just an example, for more information on intercooler options try the South West Dubs forum.
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First off was to strip down the front end of the car, remove the bumper and take off the front panel. On doing this i noticed that the horns would be in the way so i relocated them down to my inner wing where the old intercooler was.
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Then i drained the coolant, dropped my oil cooler which i fitted last year down to one side out the way, then removed the radiator, the old intercooler and all the intercooler pipe work.
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Then i had to remove the original radiator fan as it was to be replaced with an up rated spal item.
Next was to fit the new fan to the radiator, and then the brackets for the new intercooler and get the puppy bolted on there.
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Upon offering up i noticed that my so called clever uprating to a big bosch silver battery from a diesel was fouling on the new pipe work...
Not a problem though, as i put some new holes in the cross member and moved the radiator an intercooler over towards the centre of the car more increasing the airflow to it at the same time as now it sits directly behind the grille, I had to get my younger bro bonehead to fabricate me up a nice aluminium bracket for the top of the now relocated radiator though (with a std battery none of this would of needed to be done).
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