My take on the DIY Top Mount Intercooler

So I have been tinkering with my Outback XT for quite some time now and I wanted to share with everyone my take on the DIY TMIC.

 

My goals were:

 

To run a WRX style turbo, but still retain at TMIC. Easy right? Just do an STI swap...well no, not in my case. I like the OEM intake manifold on our cars. I accually think it's a better design that the STI one. Call me crazy right? On top of being a nut case, I am a cheap bastard and wanted an upgraded turbo and intercooler for as little $$$ as possible!! I also like to do things a little different than everyone else and blaze new paths..... See my brake ducting thread for evidence.

 

So, I picked up a VF39 for and all I needed was an intercooler. I searched ebay high and low for something that I could make work. I ended up finding this..

 

http://cgi.ebay.com/ebaymotors/CXRacing-RX7-Turbo-V-Mount-Intercooler-FD3S-FMIC_W0QQcmdZViewItemQQhashZitem3a511564e6QQitemZ250468459750QQptZMotorsQ5fCarQ5fTruckQ5fPartsQ5fAccessories

 

Top view

 

http://farm3.static.flickr.com/2778/4274031141_ab5d4407b1_o.jpg

 

Bottom view

 

http://farm3.static.flickr.com/2776/4274031269_af919ab7bf_o.jpg

 

The dimensions of the IC core are 15" long x 10" tall x 3.25" deep. This is a total of 487.5 cubic inches. That's over 2x bigger than the stock TMIC. Not bad IMO. With the end tanks the length is 21.5". It's bigger than the Perrin and the AVO.

 

This intercooler is made for a V Mount on an RX-7....but I measured out the dimensions of the IC and I measured the space that I had in the car and I thought it would work. So pulled the trigger and ordered it. I live in So Cal and though I could save on shipping and go pick up the IC at the Justintercooler's wherehouse. I was wrong, those son's of motherless goats won't let you do that, so I had to pay the $30 shipping charge (it's now $40 )

 

Now I just needed some piping and couplers to connect everything. I found this company -->http://www.max-redline.com/ They were cool and let me come in and pick up the pipes and couplers. I would do buisness with them again in a heart beat.

 

Here is how I routed the piping.

 

Passenger side view

 

http://farm5.static.flickr.com/4010/4274776782_dce52c77b4_o.jpg

 

Drivers side view

 

http://farm3.static.flickr.com/2753/4274776930_389d0a1d33_o.jpg

 

Top view

 

http://farm3.static.flickr.com/2801/4274031697_87b78b51a5_o.jpg

 

Turbo outlet size is 2", so the hot side piping goes like this: 2" to 2.25" step up coupler on turbo --> 2.25" 90 degree bend --> 2.25" hump coupler --> 2.25" 90 degree bend --> 2.25" to 2.5" elbow --> Intercooler

 

The throttle body inlet on our cars is 2.75" and the Intercooler outlet size is 2.5", so this is how I did the cold side piping: 2.5" to 2.75" elbow --> 2.75" pipe --> 2.75" coupler on throttle body.

 

For the BOV, I had a local welder add a 1.5" diamater nipple (you can see it about 1/2 way down on the cold side pipe). It only sticks out of the pipe about 1" or so. I did not want a LGT style flange welded directy to the pipe for the BOV so if I want / need to upgrade to a different style BOV in the future, this gives me options. So I mocked up a flange for the stock BOV and added a 1.5" diamater nipple to that as well. This also was only about 1" long. I connected the BOV to the 2.75" pipe with a 45 degree bend 1.5" radiator hose from Autozone.

 

Here is the semi finished product:

 

3/4 Drivers side view

 

http://farm5.static.flickr.com/4032/4274031849_f6bd089a59_o.jpg

 

3/4 passenger side view

 

http://farm3.static.flickr.com/2736/4274032007_8a4f7bec35_o.jpg

 

I say this is the semi finished shot only because I added a bracket on the passenger side of the IC that connects to the intake manifold. It helps hold the IC in place better.

 

Overall I am happy with this set up as it only set me back about $400 total.

 

There are problems though. The 1st is that the IC sits VERY high in the engine bay. This meant that I needed to take off the stock intake splitter on the hood. It was a minor PITA and I had to take off some of the isulation material. Even with taking off the stock splitter, when I shut the hood, it was rubbing a little on the passenger side of the IC and pinching the windshield washer line making it not work.

 

So there are two solutions to this problem. The 1st (and cheap / ghetto way) is to cut a little area on the underside of the hood so the IC does not rub. This is what I did. Hey, it's free right?

 

The proper way would be to make the IC sit lower in the engine bay. The best way I can think to do that is to make the hot side piping 2" instead of 2.25". This would make the IC sit .25" lower and therefore NOT rub on the inside of the hood.

 

If I was to do it over, I would rout the hot side piping a little different. I would do: 2" 90 degree elbow right out of the turbo --> 2" 90 degree pipe (with about 3-4" of straight pipe on either side of the bend) --> 2" to 2.5" 90 degree elbow --> IC inlet.

 

The other big problem is that with the stock splitter gone, the air is not being routed directly to the new TMIC. Don't get me wrong, most of the air will get to the IC, but it could be better. I have yet to fab something up, but I will be going to Home Depot soon enough and make some sort of custom splitter to fit the IC.

 

Sooo.....any questions?

 

UPDATES ON POST #28 and #30!

Ill give you props for ingenuity. Looks like you got a decent size core in there too. Get a good splitter working and id say you are in business.

nice work,was thinking of doing something similar..

Looks good...

Wow, way cool. Have you got the car tuned yet? What sort of powa you putting down? I loved my VF39 on my Sti. One of Subaru's best turbos imo.

Yes, I was tuned by Infamous1 here in So Cal.

 

278 WHP and 302 WTQ on 91 Octane

 

302 WHP and 352 WTQ on E85

I did the other Ebay TMIC upgrade and have recently been looking at other IC's to use (bigger, better, you know). Have you made any fitment changes? any other progress you can share.

 

Thanks

I am about to fab up a new "splitter" that will direct air better into the TMIC. I will take pics and share when I am done.

BTW, what's the "other" ebay TMIC...is it the one that looks like the Tuning Alliance one?

I am about to fab up a new "splitter" that will direct air better into the TMIC. I will take pics and share when I am done.

 

I'd like to see that. You def need a wider spread on the air flow.

BTW, what's the "other" ebay TMIC...is it the one that looks like the Tuning Alliance one?

 

yep, post 385. http://legacygt.com/forums/showthread.php?t=105992&page=13

 

It was a great project. I did the vf39 with a little twist. Infamous is tuning it and I'd like to know his thoughts on how the two IC compare.

 

Good luck

I liked how you clocked the turbo....is that hard?

It was pretty easy but you end up having to run a EWG. I'm not sure how you would make it work with your set-up, unless you flop the end tank.

Holy shit, that thing is a beast, nice work!

Very cool setup OP!

Thanks. I have fabbed up a splitter, but it's not quite done yet. Will post pics when finished.

Why are your whp numbers so low?

 

Ran out of fuel probably? Well you know what your next upgrade will be then

 

Impressed you fit that in there! BIG!

 

Edit: Interested to see your splitter.

Why are your whp numbers so low?

 

Ran out of fuel probably? Well you know what your next upgrade will be then

 

Impressed you fit that in there! BIG!

 

Edit: Interested to see your splitter.

 

Meh, I don't think the numbers are that low for the mods. This would prob be right about 300 AWHP / 320 AWTQ on a dynojet. Sounds about right for stage 2 STI to me.

 

As for the splitter, it's done. I have just been too lazy to take pics yet. Will do it sometime in the next 6 months....I promise!

 

Edit: I forgot to mention that I did do fuel upgrades (injectors and pump)

Yeah seat of the pants felt strong, then again we never measured the actual tire diameter either.

I have one of these Intercoolers if anyone is interested in taking on a DIY TMIC project. It wouldn't work for me since I have clocked my turbo.

 

What I like about this compared to the other DIY TMIC is that it is 10" in height and fits our scoops perfectly.

So I have been tinkering with my Outback XT for quite some time now and I wanted to share with everyone my take on the DIY TMIC.

 

My goals were:

 

To run a WRX style turbo, but still retain at TMIC. Easy right? Just do an STI swap...well no, not in my case. I like the OEM intake manifold on our cars. I accually think it's a better design that the STI one. Call me crazy right? On top of being a nut case, I am a cheap bastard and wanted an upgraded turbo and intercooler for as little $$$ as possible!! I also like to do things a little different than everyone else and blaze new paths..... See my brake ducting thread for evidence.

 

So, I picked up a VF39 for cheap and all I needed was an intercooler. I searched ebay high and low for something that I could make work. I ended up finding this..

 

http://cgi.ebay.com/ebaymotors/CXRacing-RX7-Turbo-V-Mount-Intercooler-FD3S-FMIC_W0QQcmdZViewItemQQhashZitem3a511564e6QQitemZ250468459750QQptZMotorsQ5fCarQ5fTruckQ5fPartsQ5fAccessories

 

Top view

 

http://farm3.static.flickr.com/2778/4274031141_ab5d4407b1_o.jpg

 

Bottom view

 

http://farm3.static.flickr.com/2776/4274031269_af919ab7bf_o.jpg

 

The dimensions of the IC core are 15" long x 10" tall x 3.25" deep. This is a total of 487.5 cubic inches. That's over 2x bigger than the stock TMIC. Not bad IMO. With the end tanks the length is 21.5". It's bigger than the Perrin and the AVO.

 

This intercooler is made for a V Mount on an RX-7....but I measured out the dimensions of the IC and I measured the space that I had in the car and I thought it would work. So pulled the trigger and ordered it. I live in So Cal and though I could save on shipping and go pick up the IC at the Justintercooler's wherehouse. I was wrong, those son's of motherless goats won't let you do that, so I had to pay the $30 shipping charge (it's now $40 )

 

Now I just needed some piping and couplers to connect everything. I found this company -->http://www.max-redline.com/ They were cool and let me come in and pick up the pipes and couplers. I would do buisness with them again in a heart beat.

 

Here is how I routed the piping.

 

Passenger side view

 

http://farm5.static.flickr.com/4010/4274776782_dce52c77b4_o.jpg

 

Drivers side view

 

http://farm3.static.flickr.com/2753/4274776930_389d0a1d33_o.jpg

 

Top view

 

http://farm3.static.flickr.com/2801/4274031697_87b78b51a5_o.jpg

 

Turbo outlet size is 2", so the hot side piping goes like this: 2" to 2.25" step up coupler on turbo --> 2.25" 90 degree bend --> 2.25" hump coupler --> 2.25" 90 degree bend --> 2.25" to 2.5" elbow --> Intercooler

 

The throttle body inlet on our cars is 2.75" and the Intercooler outlet size is 2.5", so this is how I did the cold side piping: 2.5" to 2.75" elbow --> 2.75" pipe --> 2.75" coupler on throttle body.

 

For the BOV, I had a local welder add a 1.5" diamater nipple (you can see it about 1/2 way down on the cold side pipe). It only sticks out of the pipe about 1" or so. I did not want a LGT style flange welded directy to the pipe for the BOV so if I want / need to upgrade to a different style BOV in the future, this gives me options. So I mocked up a flange for the stock BOV and added a 1.5" diamater nipple to that as well. This also was only about 1" long. I connected the BOV to the 2.75" pipe with a 45 degree bend 1.5" radiator hose from Autozone.

 

Here is the semi finished product:

 

3/4 Drivers side view

 

http://farm5.static.flickr.com/4032/4274031849_f6bd089a59_o.jpg

 

3/4 passenger side view

 

http://farm3.static.flickr.com/2736/4274032007_8a4f7bec35_o.jpg

 

I say this is the semi finished shot only because I added a bracket on the passenger side of the IC that connects to the intake manifold. It helps hold the IC in place better.

 

Overall I am happy with this set up as it only set me back about $400 total.

 

There are problems though. The 1st is that the IC sits VERY high in the engine bay. This meant that I needed to take off the stock intake splitter on the hood. It was a minor PITA and I had to take off some of the isulation material. Even with taking off the stock splitter, when I shut the hood, it was rubbing a little on the passenger side of the IC and pinching the windshield washer line making it not work.

 

So there are two solutions to this problem. The 1st (and cheap / ghetto way) is to cut a little area on the underside of the hood so the IC does not rub. This is what I did. Hey, it's free right?

 

The proper way would be to make the IC sit lower in the engine bay. The best way I can think to do that is to make the hot side piping 2" instead of 2.25". This would make the IC sit .25" lower and therefore NOT rub on the inside of the hood.

 

If I was to do it over, I would rout the hot side piping a little different. I would do: 2" 90 degree elbow right out of the turbo --> 2" 90 degree pipe (with about 3-4" of straight pipe on either side of the bend) --> 2" to 2.5" 90 degree elbow --> IC inlet.

 

The other big problem is that with the stock splitter gone, the air is not being routed directly to the new TMIC. Don't get me wrong, most of the air will get to the IC, but it could be better. I have yet to fab something up, but I will be going to Home Depot soon enough and make some sort of custom splitter to fit the IC.

 

Sooo.....any questions?

 

A man after my own heart :-) Love the DIY stuff.

Has anyone done something along these lines that works with the stock turbo?

Yes, Mike at ESP sold a kit for a while. Only difference is you use the V1 eBay TMIC some of us have, not this one, and get a WBR flange to mount to VF40/46/52. Then connect with custom plumbing.

Update:

 

I ended up re-doing the hot side piping. I was not 100% happy with the way the 2.25" hot side was working out.

 

So now the hot side piping goes like this (from turbo) --> 2" 90 degree silicone elbow --> 2" aluminum coupler --> 2" 90 degree silicone elbow --> 2" aluminum coupler --> 2" to 2.5" 90 degree elbow ---> Intercooler.

 

The intercooler sits nice and level now. I also fabbed up and splitter for the hood to direct the air into the IC better. Overall I am pretty happy with the project.

 

If you think about it, this is a poor mans STI swap. You get the VF39 (or other WRX style turbo of your choice) and a nice big TMIC.

what this cost ?? make me a set??? =)