I got started last night after taking some more measurement. It looks like there might be a slight fitment issue with the way I had planned on installing the unit. There is a wiring harness which might be in the way.

So to be sure I mocked up the new manifold/IC in cardboard and will test fit it today or this weekend; time permitting of course. I'll pull the stock manifold and fit this cardboard piece in. If there wiring harness is in the way I'll see if it can be moved slight as it appears it can once the IMRC actuator is removed.

Outside of that it should be straight forward. I'll order up the aluminum plate I need for the base mounting plate and drill it out as needed. From there I will use some sheet metal to form the main plenum and quickly torch weld it in place before having it MIG welded.

One other thing IO found out, Top-End also sells air horns for the runner attachment.

 

nice...I've been doing that too lately trying to test fit for my front mount.

 

 

Yea, it is much easier to start off with something inexpensive and pliable just to be sure.

 

great news steve good luck on fabricating

 

Hey Scalbert,

I bet if you put that on ebay, as an "UPGRADED" intercooled CLS manifold, you will get $100 for it!!!


GOOD LUCK with getting it working on your car FOR REAL!!!!

 

I pulled the manifold and did a test fit. Right off it doesn't fit; it was hitting the stock strut tower brace and a wiring harness, but not by much. However, my mock up unit does have all squared edges. So I compressed the edges some to simulate the rounded edges of the actual unit and it fit in beautifully.

I also checked the hood clearance on the front plenum and it was fine but close; too close for engine rotation. So I'll angle that part a little to give about a one inch gap.

I just need to verify the radius on the end tank by either a picture or a detailed drawing. After that I'll go ahead and purchase the unit.

Pictures are below:

 

Steve... please check to make sure the hood closes!

 

I did, I used some clay on top of the box at various points to check clearance. As mentioned, it was tight and will require a slight change but after that there will be at least an inch throughout.

 

Maybe he is thinking of doing a HOOD SCOPE like this one??

 

Scalbert....is a top mount the only place where there is room? Seems kinda counter productive without a hood scoop no?

 

It is a liquid/air IC, not air/air. There will be a large heat exchanger for the coolant behind the lower fascia.

 

steve, you rock.


i'm excited to see this project moving along, for more than one reason.

 

You're the shiz!

 

Woohoo, just got confirmation on the aluminum plate for the base of the plenum. I'm getting two just in case I mess up on the first one.

The aluminum plate measures 1.1" x 3.5" x 13.0" The problem is to take my time to precision drill it...

 

 

Nice work Steve! Do you have a drill press?

 

gotcha...I assumed too much. Looking good.

 

Of course...

 

Too cool!

 

The main tools I will be using are the drill press, table saw, band saw and rotary grinder. I may try to do some of the welding as an experiment as I haven't done much this and would like to learn; I need to track down a torch though.

 

Put that rig on your 3.5L upgrade with your S/C too and you'll be running down Vipers and the like!! Keep up the good work.

 

Below is the size air horn to be used. I kept mulling this over numerous times trying to decide on the size to use. In the end I used a shorter unit which will decrease the runner length over stock. However, since we are using a roots style blower with excellent low end performance, the potential torque loss would be negated. But the upper end might actually be helped to further extend the torque before dropping off.

The height is about 1/3 of the chamber height with decent radiused edges.

 

As usual, the price is creeping up higher and higher as I get into it more and more. Here is the rough break down so far:

$650 - IC (with vacuum port attachments)
$250 - Plenum (with MAP and IAT ports)
$150 - Air Horns
$50 - Pipe and Couplings
$50 - Pump and Hose
$50 - Reservoir
$150 - Heat Exchanger (high capacity oil cooler)

That is $1350 total. I hope we can get this down some but there is not much room to work with in these items. But in relation to other complete IC kits, this is quite reasonable.

 

Rent one, I know that there has to be a hardware rental place around u somewhere.






Juker008

 

I'd like to have one around all of the time but did consider renting.

 

... looking like it is all coming together.


Hope your letting the places that you deal with know that there is a trail right behind you that will be buying more of their parts...

It just might get you a reduced price...

So far that has worked for me..LOL..

Smitty

 

That is some nice R&D time you've put in. So are you going to offer this as a kit for other S/C owners to make some money??

I looking into doing a custom FMIC for my S too, because CT is taking their sweet ass time coming out with the aftercooler.

 

Thanks, it is a fun project. As for offering this and making money; I planned on making a few for some of us here only. If the market and demand is there I would have to be compensated for making additional units. Or let someone else make and sell them, maybe with a kick back.

 

May I suggest,....have those few you are going to put these kits together for,....buy the torch for you,......please!

 

i dunno how you squeeked that in there without removing the tower brace, but I keep looking at it and it looks AWESOME...

 

Sure, here you go:

Welding Kit

JK, actually my father-in-law has a torch kit if he can find it. I plan on just tacking it in place and then taking it to a guy to either MIG or TIG weld it inside and out.

 

There should be some clearance; I want at least 1/2 inch. But this precludes the use of many common aftermarket strut tower braces though. Except for the Nuespeed; from what I recall it goes behind the stock bar.

 

im in steve.i cant wait also to see the results of the tb.king told me they reposition the sensor for optimal performance and make it adjustable i guess that will get rid of the lag in first gear.

 

I'm not sure if I noticed any change in the response of the throttle; at least nothing jumped out at me.

 

yes but steve didnt feel a little more power with the new tb?

 

Nope, no power gain felt. Nor did I expect to. Even being generous with a 10 WHP gain, that is only a 3% difference. Not really enough to feel.

 

so i guess it will be worth it once the ic is done

 

IMO, it is worth it now. The flow numbers support the need for it and it is certainly one of the more reasonably priced mods.

 

wow the time and knowledge it takes to engineer these projects, i'm really in awe. Hats off to you and good luck.