PHOTO'S relocated charger!!!!

[217gsr]

Are you going to use some sort of gasket ala-Hondata intake manifold gasket in between the the blower and the intercooler?

Is the intercooler going to be water cooled? [img]smile.gif[/img]

[SC HYBRID]

yes, it will be an air to water intercooler.
i just finished talking to one of the guys at spearco and he said the minimum thickness for an intercooler can be 2.5 inches. ive only got 2 inches right now and thats pushing it. my alternator is pushed all the way forward now, and thats with 1/2 of the bracket cut down. i could probably steel a little more off the alternator bracket, but no much.i ve got the hondata gasket on the way also which should bring me off the cylinder head some more. i need to find a way to gain 1/2 inch more. i could add an aluminum spacer between the cylinder head and new hondata gasket, but it needs to be approx. 1/4" or 1/2" to get me the clearance ill need.
heres where ill need some input from all the hostboard members::::

1. where can i purchase a spacer to go between the cylinder head and intake manifold ? (this will be used to gain the extra 1/2 of clearance i need to lower the charger. and no, i dont want to add (2) hondata gaskets.....i dont think it will seal properly.

2. Spearco tells me it will cost roughly $1000 to manufacture the intercooler. this does not include heat exchanger up front, water pump, fan, switch, accessories,oil filter relocation kit, etc.

where else can i get an intercooler made (air to water) that will be a little more cost effective ?

[CivicR]

SC HYBRID...I know a while back that someone here on the board posted about another company that was doing what you are doing with the water to air intercooler...this guy was buiding the exact same setups as you just not on our cars...on an american car....maybe he would have a cheaper core since he is buying them in quantity...unfortunately I dont remember the companies name...but maybe this will spark someone elses memory and they will know?

[SC HYBRID]

i just realized, i still have my original intake manifold. i wonder if i can cut off the plate on the original manifold ??
i could use it as a spacer to get the clearance i need.

[BoostedEX]

You're going to need longer head studs for the manifold since you are looking at putting a spacer in there also........

ZIP added longer headstuds when he installed the Hondata gasket.

BTW: Here's a shot in the dark....maybe you can go and talk to someone or even look at the Ford Lightning M90/Intercooler setup they have and see where they got there core from!?!?!? Just a thought.

<font color="#a62a2a" size="1">[ March 29, 2002 10:18 AM: Message edited by: BoostedEX ]</font>

[5 Liter Eater]

Don't know if this helps but here is a page about a company that makes an intercooler for the GTP Grand Prix's which use the same Eaton as us (except it's an M-90). It's pretty close to what you're trying to accomplish so maybe they could help you wrangle up some parts.

http://www.thrasher-ep.com/l67_htm/new_cooler.shtm

<font color="#a62a2a" size="1">[ March 29, 2002 10:48 AM: Message edited by: 5 Liter Eater ]</font>

[SC HYBRID]

ive already checked with the "THRASHER" company. i got the phone number off the net and called them, the guy who answered the phone said " i dont know nutin' bout no intercoolers" DUH!!!
and as far as checking out an F150 lightning, ive checked the internet for every possible location for air to water intercoolers, from jaguar, porsche, saab, merkur, Ford lightning, Ford thunderbird, and especially the Pontiac gran Prix, the gran prix is exactly what im looking to do!!!
im gonna post a pic of their website now!!!

[SC HYBRID]

man, im still working on getting the charger lowered another 1/2". i just finished hacking up the alternator bracket some more, and actually hacking off a small part of the alternator itself!!!
im almost there, i almost got the extra 1/2" i need for the cooler to fit. the last things i need to do for it to fit are:
take the alternator to my local machine shop guy and he's gonna shave down the backside of the alternator bracket about a 1/4", then i need to shave down 1 of the bolts on the charger itself.
man, theres so much shit to custom make to get this to work.
BTW, i just got the hondata gasket today and it fits ok, but i will need to bore out some of the port holes.im gonna drill out the coolant hole so the car doesnt overheat.
well, tomorrow ill finally finish up geting the charger lowered to 2 1/2" successfully.
then i have to draw up exactly how the intercooler core will be built.spearco's guy will then setup actual drawings on CAD.
ill update yall later and include more photos later tonite!!!

[93SleepR]

I took a look at that pontiac intercooer link and it looks like just the thing you need. If you can get the 2.5" needed to make it fit.

The rest of the plumbing is easy. I have already done some research on 12volt pumps, radiators, water tanks, etc. You should check out a company called McMaster Carr. They have more parts/supplies/tools than any other place on the planet

http://www.mcmaster.com/

Good luck!

Mike