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V5 i/c now replaces V1 i/c
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Old 11 Dec 2005, 12:36 PM   #1 (permalink)
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Talking V5 i/c now replaces V1 i/c

At last the mod is complete and i never want to do this again

As the title says i decided to upgrade my intercooler from the old slanty type to the proper tuned sti type (V4). I bought the i/c of ebay (60) and purchased TCS22 samco hose (48 from scoobyparts). So the first mod was to remove the elbow of the i/c and have it blanked off via some TIG welding (thanks to Flavell welding 01642 678808 10) and the next step was to clean up and straighting some of the cooling veins.

Old i/c before the tool box came out!

New i/c wouldnt fit so a little mod to the bodywork was needed (rubber hammer and a hacksaw) to help fold the metal work!

Out with the old and in with the new...

Then chop a large chunk of the hose to help make it fit...
Now this bit was a complete nightmare, there was now room to fit the hose (i/c to t/body) so large hacksaw was needed... about 6mm was taken of the i/c and also the t/body (made sure no metal deposits was in the i/c and t/body). Then the next nightmare i had was trying to get the hose onto the turbo with a lot of patience it finally went on.

The end result...

The next thing to do is to make up a bracket to hold the i/c to the engine,that'll be fitted tomorrow when im at work!

After a few test runs in the car the boost gauge is down 1 psi, had a look this morning and the hose from the turbo to the i/c is a little distorted (flat). Wonder if the hose does expand when coming on boost. I'll keep a eye on that and if probs occur then the old i/c will be going back on.

I read a thread that someone fitted a V5 i/c to a classic and was wondering if he had the same problem.

Would of posted more pics but im limited to only 4!

Have fun anyone who's gunna do the same mod!!!!
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Old 11 Dec 2005, 01:44 PM   #2 (permalink)
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good job m8 - well done well documented... like the hoses too
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Old 11 Dec 2005, 02:09 PM   #3 (permalink)
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Congrats on replacing your old i/c with the V4 (great looking job that) & I hope you get the hose problem sorted out.

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Old 11 Dec 2005, 05:39 PM   #4 (permalink)
Obsessed Scooby
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Reminds me a bit of this thread.


Looking good mate.
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