Started final fitting on mine today. Thought I had it pretty well measure out and marked. Put a pair of pop-rivets in it and checked fit, there's a gap up top! It's not very large but after pondering I think I'm going to redo the fit again and try to eliminate it. I'm not sure how much, if any, pressure builds above the intercooler but I'm going to do my best for as near a perfect fit as possible.

What I've done so far is simply slice through the duct horizontally and slide the top piece into the bottom. This forces a slight gap but I believe I'll be glassing this when I'm happy with the fit. The lower duct required a little trimming for the outlet hose and because I've got a sensor bung in the way. I need to bolt those sensors on to see if they will cause any issues, hopefully running wires to the passenger side intercooler won't be too tough. I'm ready to be done with this job already and still have the driver's side yet to do

 

I would suggest to anyone looking to upgrade their intercoolers. Choose a reliable shop or tuner first and then with their input, choose your intercoolers. Like Markski said, too many variables to compare with anyone else car.

 

exactly,
every car has its own story, be it on E85, 91 or 93 gas, small k16 billets in cooler less humid europe to hot Texas with 30rs plus on a built motor.
bottom line is good proven cores and some decent end tanks with flanges that dont leak and pressure tested and you will be fine... just make sure know where the cores are coming from because I can save $500 and get cheap cores and pretend like they are well made. there is no magic here...

 

A little more fitting tonight and found an area or two where the duct had been interfering. Yet another round of pop rivets and tweaking and the duct now SEALS properly to the fenderwell duct! Irish100P was a huge help with the fiberglass and now mine is nearly done on one side. I will need to find a source for good foam seals to replace the old ratty ones and I will need to find a way to attach the lower duct (likely zip ties sorry purists) and I'll have one side done. I predict the second side will go way more quickly. Worth the added time to fit these in well

 

Cut the stock metal straps in half and rivet an aluminum center section to extend the straps. Permanent OE solution...

[url=https://flic.kr/p/dJwgLa]

 

^ That looks nice, would hardly know it wasn't factory.

 

rmc lets do the shortlist shall we, and ask. which of pwdrs mods do NOT look nice lol

i have decided upon the 7.2 i/c's to partner with my ever trusty old skool 16/24's and new injectors, and am hoping and confident at the same time i have made the right choice. once i actually DO IT. but also hoping to pair this "upgrade" with new inlets

 

Mark dont get the 7.2s wagners better for u IMO plus when u get an urge for 4.5s its an easy step up like i will be doing sooner or later with the rabbits 4.5s.

Mark you may as well just get the rabbits 4.5s now you cant have a to big cooler. If i had had that choice when i got my wagners of would of gone with the 4.5s straight away.

2k for rabbits 4.5s dont think u can go wrong there Mark if the rabbit throws in some hoses and shipping hey Sean??

 

im not going for big hp #'s but am always looking for smart choices and deals lol.

but really like to oem whenever possible on an upgrade. but will compare, and yes, to hoses etc included. cool stuff.

the wagner stuff i saw at ams did seem to incl all hardware/hoses for 1300+. not bad. but i'll be looking into srm as well, owing to the rep and i also like to support indie anything. thx tim.

 

Mate do the 4.5s i know you will be really happy if u do

 

I dont want big hp either 6 or 700 is enough for me down under but you cant go wrong with big cooling on a boosted 996T

 

got that right. expecting 105's often here soon. well, that an el nino weather event for months ahead ( thx god lol ).

who knows. if it does actually RAIN here perhaps i'll use the downtime to do all this sh*t i cant afford .. yet... NEED argh

 

 

DOH!!! Great IDEA pwderhnd!!!!! Why didn't I think of that!

 

Aw man, I'd seen that strap idea before and had completely forgotten about it - THANK YOU! I'll be doing that this weekend I expect. That will make like much much easier. I'll try to post pics of my duct soon and maybe an install pic with the SRM cooler. Need hoses to complete the install but I can begin work on the other side shortly - woohoo!