Mounting the intercooler required chassis modifications and quite a bit of custom bracketry. A steel cross-tube and a couple of aluminum brackets were fabricated to hold the rear of the intercooler. The front of the intercooler is held up by part of the chassis and another aluminum bracket. Part of the front bumper mounting surface was removed to make room for the intercooler and a new one will need to be made to replace it in the future.
It's about time we get this beast mounted. Starting up front, two M8 threaded weld bosses were machined and a piece of 0.090″ 5052 aluminum was cut and bent to make the mounting bracket. The bracket is secured to the frame with a couple of M8 rivnuts. Apologies for getting excited and forgetting to take pictures of the steps leading up to this point. Don't worry, we'll make up for it from here on out.
Part of this intercooler setup requires the modification of the Borg Warner turbo's compressor housing. Here we have cut off the end of the compressor outlet and tacked on a 2.5″ tight radius cast aluminum elbow from Vibrant Performance.
The cast elbow completely welded on and the compressor housing reinstalled to the turbo.
When you are making parts from scratch you have to start somewhere. This is another piece of 0.090″ 5052 aluminum sheet and will be one of two mounting brackets for the rear of the intercooler. Sections marked with an “X” will be cut away and lines marked with an “X” are where the sheet will be bent.
Skipped a couple of steps, but here we have the cut and bent rear mounting brackets that are ready for welding.
Rear mounting brackets sitting on the cross-tube while a piece of wood continues to support the intercooler core.
This shot gives a better idea how the rear mounting brackets attach to the cross-tube. Basically there is a piece of steel channel straddling the tube. After the channel is fully welded to the tube (currently just tacked in the picture) it is drilled and tapped for two M6 bolts per mounting bracket.