Install A Cooler ?

[mr_crust]

hey guys,

im looking a changing my stock cooler for a new one (600x300x76) now i got no idea how to mount it at all. Does anyone have a guide on how to do this or a link, it would be much appreciated. Also pics will help

-DAZ

[mr_crust]

www.greddy.com/tech/RSX_S_IC31.pdf

^^^this is for a integra, but it should it be similiar to a skyline ??

[Slide]

If it is a hybrid style Cooler

Than on the top of the rio there are 2 holes that the cooler lines up with perfectly for the bolts to screw through it into the cooler.

You should have 2 metal straight brakets aswell that go on the bottom from the 2 holes to the splash guard holes.

Just undo the screws then rescrew them back in with the braket in between.

I made up 2 small brakets for the top so the cooler sits back more.

You will have to cut the rio to fit the cooler much like in the pictures completely removing the lower portion of the bar.

Edited November 18, 2005 by Slide

[wessa02]

I did mine last weekend, I dont have any links or photos, but I can run you through step by step. First remove the stock intercooler front bar etc. The stock cooler is located underneath the airbox. depending on what New cooler kit you got depends on how much of the origanal piping you will need to use with your install. now you have the origanal cooler out get the new piping and lay it out in front of the car and try and work out which pipe goes where (if you would like I can take pics of mine and send them to you to make it easyer) as a verbal aid (take into account that your kit maybe different from mine) from the turbo a pipe goes down through one of the holes where the origanal cooler piping was and onto one end of your new cooler. On the other end of your cooler you should have a pipe that does a 'u' bend then there will be a pipe that does a 's' bend then the last pipe should be in the form of an 'L', this pipe above the main fan and connects to the intake of the engine. Make sure yuo wash the pipes out before installing them and constantly check for filings.

As for physicaly mounting the cooler, I used a die grinder and an angle grinder to cut holes and a hack saw to cut up some brackets if you dont have them with the kit already. Take the front bar off and I also took the headlights out as well. you will have to grind away parts of the reo bar (the metal bumper behind the front bar), you will also have to relocate the horn and trim the a/c fan which is mounted on the front of the radiator. I used some bits of angle steel on the top and some flat steel on the bottom to mount the cooler (for pics of exactly how I did it let me know and I will take some). below the washer bottle you need to cut a hole about 1/2 to a full inch bigger then the pipe that needs to go through. See how you go with that any troubles just pm and I will helpyou best I can

[mr_crust]

Thanks Slide and wessa02 for the info, i cant thank you guys enough. once i get my cooler done, ill do a full right up for future reference. Also have guys experience any problems with a larger cooler

[wessa02]

I gota 600x300x75 I had to chop a fair bit out but nah raped it for the last week to make sure nothing is going to fall off or blow up before the big skyline charity cruze this weekend and so far so good

[mr_crust]

quick question (sorry if im a pain in the ass) but where u run the cooler pipes under the washer bottle, where do i cut the body of the car, have u got any pics at all? and do you have to relocate the washer bottle?

Edited November 20, 2005 by mr_crust

[Blitz]

quick question (sorry if im a pain in the ass) but where u run the cooler pipes under the washer bottle, where do i cut the body of the car, have u got any pics at all? and do you have to relocate the washer bottle?

No need to relocate the washer bottle!

Dummy fit the crossover pipe that runs down to, and through the guard under the washer bottle to get an idea of where to position the hole.

Under the washer bottle there is a very thin section of guard that you cut through using a 3 inch hole saw.

[Bliksem]

Just to help you a bit more I used a 75mm Hole saw, I dummy fitted the relevant pipe and cut a hole from outside of the engine bay (I removed the drivers side wheel for this) as its a bit hard to get a drill down there in front of the fan. Then I applied some primer to the bare metal and layed a piece of rubber tube around the hole with a slot cut on one side to protect the piping and to stop any rattles.

Hope that is informative.

[woolls]

<_< tried to attach some pics, but won't let me???

Edited November 21, 2005 by woolls

[Damo]

http://www.hybrid-power.com/installation_/GTS/GTS kit.pdf

Try this link for generic intercooler installation.

[ossie_21]

I installed a hybrid (seems this is what you have) myself with minimal trouble, did take a while though. If you need to cut the fan blades CUT AT AN ANGLE!!!!!, then you don't have to cut "that much" off. Some people hate the fact you need to cut these, but it's just part of working with a budget. Here is a couple of pics, and it will give you an idea of what I mean. Added one of the clamps too.

[mr_crust]

if u cut the fan blades, will that cause it to be unbalanced?

btw thanks for all this pics, they make it so much easier...i really want to c a pic where u cut the whole and run the pipes near the washer bottle if anyone has that.

[Slide]

The hybrid pdf file shows where to cut the hole in the chassis underneath water bottle.

And aslong as you take a similar or as close to amount off each fan blade it wont be noticably unbalanced.

Every single person with a hybrid style kit has cut fanblades and i have never heard of somebody doing that bad of a job that it has snapped something like the water pump output shaft or anything because of it being unbalanced.

Sorry about quality of pics

Only have a camera phone at this house

Edited November 22, 2005 by Slide

[Bliksem]

i'll take a photo now for ya dude

EDIT: Here u go. Mine's a D1 Kit, but my understanding is that these are the same set up as the Hybrid Kits.

Close Up of Hole (Note Washer Bottle Was Modified Near Screw)

Note: I Used a 75mm Hole Saw, Seems to be a nice Fit, not too Sloppy. Then coated the metal with a matching primer and covered the hole with a rubber tube with a slit cut along one side.

Hole Showing Radiator Hose And Washer Bottle

Engine Bay Also Showing Modified Fan Blades

Note: Fan Blades Were cut with a pair of side cutters, some pruning cutters for plants will probably do a similar job.

God that took a while on Dial Up... Hope that helps

Edited November 22, 2005 by MintR33

[Damo]

btw thanks for all this pics, they make it so much easier...i really want to c a pic where u cut the whole and run the pipes near the washer bottle if anyone has that.

<{POST_SNAPBACK}>

Ummm, see previous post of pdf file. It shows exactly where to cut the hole.

[mr_crust]

thanks again guys, i am very appreciative of every's advice and photos, to help make my installation easier.

Once i do my kit (i ordered it today) i will install it and make a step by step guide for future reference.

thanks again to everyone who helped me out

btw damo, the link to the pdf file doesnt work

Edited November 22, 2005 by mr_crust

[Cubes]

Unsure if it can be done on an R33.

My route:

Out of the turbo follow the stock ic piping in to the front bumper, 90degree bend towards the front of the car a couple of little bends equalling another 90degree bend, this heads across the front of the car slightly behind and down from the IC Core, but still level with the bottom of the bumper. It then throws a 180degree bend in to the intercooler. The cooled air then has a very short trip leaving the FMIC on the passengers side to the cross over pipe via the stock piping route.

If I were to use a 'kit' as many have here, I would most definitely look at modifying the piping kit so the air travels in the opposite direction to its current design. That being, out of the turbo across the radiator in to the front bumper then in to the right hand side of the FMIC. Cooled air leaves FMIC from the passengers side up via the stock piping route, past the airbox in to the cross over pipe.

Hot air travels faster as a result less lag through the longer piping compared to a cooler charge; Well, I would assume so without knowing much about flow dynamics. The difference is probably nothing, maybe its not.

PVC piping is nice to use when setting up pipe work, makes it easy to take it to an exhaust shop and having them welding up the ic piping.

Just don't drive around on it like some one here on SAU did... lmao..

Edited November 22, 2005 by Cubes

[Beeble]

try http://www.hybrid-power.com/installation_/GTS/GTS%20kit.pdf and then the link works

Excellent guide!

[mr_crust]

Well my cooler n pipes were delievered this afternoon. I was actually shocked how fast it arrived. I got it from JustSR, and i would recommend them highly.Here are a few pics of the cooler n pipes.

Anyone know how to get words sprayed onto the cooler? I wanna get my plates sprayed onto it...Is it just done with a stencil n normal spray paint??