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Old 02-26-2012, 06:33 AM   #1
kdog_x
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Intercooler... Bigger??

I'm looking to upgrade my stock intercooler for my D1SC. Looking at the available options, I see that most are roughly the same height as the stocker (12.5"), but about 7-8" longer (31"). Judging from old pictures I have, this looks like it could be worked around if I get one that has two bottom outlets since there is 6 or 7" of 90* tubing on the drivers side which could be changed.

The other option I'm seeing is that there are 4" thick models available instead of the stock 3" thick. Has anyone used one of these 4" thick intercoolers? Just curious if it would install smoothly? I dont mind changing the intercooler piping to a different configuration, but I'd like to keep the bumper brace and other components where they are.
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Old 02-26-2012, 11:52 AM   #2
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Quote:
Originally Posted by kdog_x...View Post
I'm looking to upgrade my stock intercooler for my D1SC.
Just curious if it would install smoothly? I dont mind changing the intercooler piping to a different configuration, but I'd like to keep the bumper brace and other components where they are.

Several configurations..from original PC IC w/ the P-1SC-1 to PC Race IC w/F-1A.
Also, different configurations/location for the PC Race Valve.

This is not a plug and play change. Installer did the work and had all the needed tools.
You'll be hard pressed, if even possible, to keep the bumper brace.

12/2009 Original PC IC...add PC Race Valve


03/2011 No changes, just a different view


10/2011 new PC Race IC... considerably larger than original IC


10/2011 relocate RV to passenger side


02/2012 relocated RV to driver side, per PC recommendation
Attached Images
File Type: jpg 2009-12-15_001-add_pc_RV.jpg (57.9 KB, 808 views)
File Type: jpg 2011-03-02_001-pc_IC_RV.jpg (84.9 KB, 810 views)
File Type: jpg 2011-10-13_001-pc_old-new_I.jpg (68.1 KB, 817 views)
File Type: jpg 2011-10-24_001-new_IC.jpg (69.2 KB, 818 views)
File Type: jpg 2012-02-14_001-new_IC.jpg (64.9 KB, 810 views)
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Old 02-27-2012, 08:00 PM   #3
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Looks good! Where did you mount the race valve once you went to the race intercooler? Is it still on one of the pipes coming right off the IC?
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Old 02-27-2012, 08:10 PM   #4
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Originally Posted by kdog_x...View Post
Looks good! Where did you mount the race valve once you went to the race intercooler? Is it still on one of the pipes coming right off the IC?

This is where it's been placed. It's amazing just how much forced air it pushes out until closing at WOT.
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Old 02-28-2012, 04:05 PM   #5
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Oh, I missed it in the earlier pic! Looking at that I guess the keeping the bumper brace is completely out of the question!!
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Old 02-29-2012, 08:58 AM   #6
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You can keep the bumper brace as I did, and i used a 4in thick 36x12x4 intercooler. i just trimed out where the intercooler was hitting the brace, and put it back on the car. check out the attached pic. it just depends on what tools you have avail to do the work.
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Old 02-29-2012, 10:05 AM   #7
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I wouldn't want the bumper brace their blocking the intercooler.
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Old 02-29-2012, 11:11 AM   #8
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Originally Posted by ls2 goat...View Post
I wouldn't want the bumper brace their blocking the intercooler.

This, that bumper brace isn't going to save anything lol. And I haven't noticed any downsides to not running it.
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Old 02-29-2012, 07:23 PM   #9
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Wow thats huge! What are the dimensions and who made it? Was fab fairly simple or a nightmare?
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Old 03-01-2012, 12:05 AM   #10
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Bumper On.... No Brace
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Old 03-01-2012, 04:18 AM   #11
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Originally Posted by kjhallex...View Post
This, that bumper brace isn't going to save anything lol. And I haven't noticed any downsides to not running it.

If I wreck, I am wrecking big. That bumper brace is not going to do a damn thing for me/you. What is the point of increasing the surface area of the IC only to block it with a bumper brace?
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Old 03-01-2012, 04:27 AM   #12
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Quote:
Originally Posted by Ret NYCPD...View Post
Bumper On.... No Brace

That looks really good, what's the specs on it? Size? Etc.

Quote:
Originally Posted by ls2 goat...View Post
If I wreck, I am wrecking big. That bumper brace is not going to do a damn thing for me/you. What is the point of increasing the surface area of the IC only to block it with a bumper brace?

Truth lol, there's going to be alot more to worry about than a IC. How's the car coming?
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Old 03-01-2012, 06:39 AM   #13
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Quote:
Originally Posted by Ret NYCPD...View Post
Bumper On.... No Brace

Looks menacing. Very nicely done sir.

Quote:
Originally Posted by kjhallex...View Post

Truth lol, there's going to be alot more to worry about than a IC. How's the car coming?

The Unicorn is doing what it does best. Making my life hard as usual.
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Old 03-01-2012, 07:31 AM   #14
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Quote:
Originally Posted by kjhallex...View Post
That looks really good, what's the specs on it? Size? Etc.

The exact specs/dimensions I don't know off hand, and can't measure as the bumper is on the car, and currently in my garage waiting for the next opening at the shop.

Its a ProCharger Race IC, if that's any help.
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Old 03-01-2012, 07:46 AM   #15
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Originally Posted by ls2 goat...View Post
Looks menacing. Very nicely done sir.



The Unicorn is doing what it does best. Making my life hard as usual.

At the moment, looks are deceiving (LOL). Thank you for the kudos.

So, your Goat is being a little uncooperative.... better the Goat than your wife if your married, or girlfriend if not married, or may be a combination of both (LOL). I'm sure cooperation is not far off.

Relevant to the injectors we recently touched on.... had a conversation with the vendor, but from a tech standpoint, I kept falling off the same page. My installer spoke with him and they were on the same page. Based on that conversation, a couple of changes will be made in the fuel delivery system. For a little more detail...click.
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Old 03-01-2012, 09:30 AM   #16
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Originally Posted by Ret NYCPD...View Post
At the moment, looks are deceiving (LOL). Thank you for the kudos.

So, your Goat is being a little uncooperative.... better the Goat than your wife if your married, or girlfriend if not married, or may be a combination of both (LOL). I'm sure cooperation is not far off.

Relevant to the injectors we recently touched on.... had a conversation with the vendor, but from a tech standpoint, I kept falling off the same page. My installer spoke with him and they were on the same page. Based on that conversation, a couple of changes will be made in the fuel delivery system. For a little more detail...click.

And here I thought you were boost referenced and running out of injector. Going to a boost referenced setup will give you some room for sure. When I was running those 103's we had the same issue, went to a boost referenced setup, and still had them maxed out. For that reason I am now running the 160's.
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Old 03-01-2012, 09:53 AM   #17
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Quote:
Originally Posted by bRAZENLS2gOAt...View Post
You can keep the bumper brace as I did, and i used a 4in thick 36x12x4 intercooler. i just trimed out where the intercooler was hitting the brace, and put it back on the car. check out the attached pic. it just depends on what tools you have avail to do the work.

I have the same size IC as you do. Pic in sig.
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Old 03-01-2012, 10:07 AM   #18
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Mine. I have the technical drawing but it is too big to attach on this site. If you need it PM me your email and I will share out.

Specs are 24'' (27'' with inlet/outlet)X13.6''X4.5''



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Old 03-01-2012, 01:51 PM   #19
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Originally Posted by ls2 goat...View Post
And here I thought you were boost referenced and running out of injector. Going to a boost referenced setup will give you some room for sure. When I was running those 103's we had the same issue, went to a boost referenced setup, and still had them maxed out. For that reason I am now running the 160's.

So, you also weren't boost referenced when initially using the 103's....
then switched to a boost reference system and maxed them out thereafter. Wow.

Vendor has had several eng builders use the 103's making 1200+ RWHP and had room to spare.....based on that, once we switch over to a boost reference system.....vendor believes the 103's will be fine.....if not, that is covered. Damn, you still ran out, oh my, you have a beast on your hands.

Nice pic's of your IC.... where did you put your race valve?

Almost no uniformity from build to build, parts to parts....different installers/individuals find a way to make things fit. Had my wife been present, she would have passed out at this sight. I just bit my lip. LOL

It wanted to play hardball....installer calls little brother to swing the big stick


Wamm, Bamm, and End Result. Wasn't that quick. LOL
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Old 03-01-2012, 03:43 PM   #20
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Originally Posted by Ret NYCPD...View Post
So, you also weren't boost referenced when initially using the 103's....
then switched to a boost reference system and maxed them out thereafter. Wow.

Vendor has had several eng builders use the 103's making 1200+ RWHP and had room to spare.....based on that, once we switch over to a boost reference system.....vendor believes the 103's will be fine.....if not, that is covered. Damn, you still ran out, oh my, you have a beast on your hands.

Nice pic's of your IC.... where did you put your race valve?

Almost no uniformity from build to build, parts to parts....different installers/individuals find a way to make things fit. Had my wife been present, she would have passed out at this sight. I just bit my lip. LOL

It wanted to play hardball....installer calls little brother to swing the big stick

That is correct. I know John (FIC) had made 1200 on an engine dyno with the 103's. Never heard of them making 1200RWHP with them. John will take care of you either way. You can see the race valve here.


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Old 03-01-2012, 06:26 PM   #21
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If you have room put a Super Chiller on it. Add an in line water to air Intercooler after air to air cooled by Chiller. Refrigerated water to air will lower IAT more than any solution out there. With air to air taking edge off then ice cold water…. well you get the idea.
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Old 03-01-2012, 08:16 PM   #22
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Originally Posted by ls2 goat...View Post
That is correct. I know John (FIC) had made 1200 on an engine dyno with the 103's. Never heard of them making 1200RWHP with them. John will take care of you either way. You can see the race valve here.



May be wrong in adding RWHP to the number John gave. Not only was I impressed with John, my installer was also. Easy fellow to converse with.

Why did you locate the RC there?
Mine was initially located on the driver side per PC recommendation. When adding the new PC IC... someone from PC recommended the passage side. Then another call to PC....resulted in recommending it back to the driver side. Don't believe the PC rep was the same one each time.

My installer felt it would be best to locate it in the same area as you have yours, but followed PC and their reasoning. Installer still believes we should have some sort of blow-off valve in the area of your location. And the Beat Goes On. LOL

Next.... is that blue tape wrapped around the breather on your valve cover?
I hadx mine tilted like yours, but went back to straight up. Reason, oil mist was finding it's way out when it was tilted, and leaving oil stains on the hood.
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Old 03-02-2012, 04:13 AM   #23
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Quote:
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May be wrong in adding RWHP to the number John gave. Not only was I impressed with John, my installer was also. Easy fellow to converse with.

Why did you locate the RC there?
Mine was initially located on the driver side per PC recommendation. When adding the new PC IC... someone from PC recommended the passage side. Then another call to PC....resulted in recommending it back to the driver side. Don't believe the PC rep was the same one each time.

My installer felt it would be best to locate it in the same area as you have yours, but followed PC and their reasoning. Installer still believes we should have some sort of blow-off valve in the area of your location. And the Beat Goes On. LOL

Next.... is that blue tape wrapped around the breather on your valve cover?
I hadx mine tilted like yours, but went back to straight up. Reason, oil mist was finding it's way out when it was tilted, and leaving oil stains on the hood.

The Race Valve has been there since the 427/F!c. On the 402/D1 it was located where you have yours. I will probably add a Wastegate in where your RV is located and play around with Boost by speed/boost by gear here when I have time.

That is actually a shop towel held on with a tie-tie. Gotta keep that oil mist contained.
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Old 03-04-2012, 05:59 PM   #24
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Here's mine.. 31x12x4 I believe..



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Old 03-06-2012, 02:41 PM   #25
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Here's mine.. 31x12x4 I believe..




Love that hood,
is it a one off , if not who makes them ?
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Old 03-12-2012, 01:53 PM   #26
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Cool, I think I'll probably go with the 4" thick one then. Just wanted to see if I was in uncharted waters trying to cram it under there, sounds very doable. That bigger intercooler looks tough behind the grilles
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Old 12-09-2012, 04:57 PM   #27
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I stumbled across this thread while looking for ideas for my recently purchased D1SC, post number 25, that is just sick looking. 31x12x4 seems to be a common size for intercoolers.
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Old 12-12-2012, 06:47 AM   #28
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Quote:
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I stumbled across this thread while looking for ideas for my recently purchased D1SC, post number 25, that is just sick looking. 31x12x4 seems to be a common size for intercoolers.

As long as we are bringing it back:





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Old 12-16-2012, 04:55 PM   #29
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^^^ I dig that ^^^
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Old 12-17-2012, 08:54 AM   #30
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Mine is very similiar.

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