Hi guys

I bought my 510 a few years and the previous owner fitted the intercooler infront of the radiator
support pannel,And has hacked up the grill to fill in space on either side,
now my question is how do you fit the intercooler behind the grill.
I have a picture but unsure on how to add it.

use a 450 x 300 x 76 front mount cooler with 3 inch outlets. take the grill and if you want you can take the valance off too. simply place the cooler on the front of the car with the outlets on the bottom. all a gap of a couple of inches from the top of the radiator support panel so the bonnet latch can still work properly. mark out the shape of the intercooler on the rad support panel. Use a grinder to cut the metal out from the rad support.

to mount the cooler u can go the easy way and drill 2 neat holes in the top of the rad support and use the appropriate sized bolts to fasten the top of the intercooler to rad support and bend up 2 L brackets to mount the bottom of the cooler.

the harder way and neater way is to mount 2 small L brackets underneath the rad support and attach it that way so you cant see the bolts holding the cooler in place. If you do not wish to cut your front valance at all u can mount the cooler further into the engine bay and move your radiator back closer to the engine.

If you fit the cooler this way you will be able to fit the cooler without altering the look of the front of you 1600. Only cutting is required is to the rad support which if its done properly will look like its from the factory.

Hope this makes sense... its pretty hard to explain.

^^^

Good description.

Check out the following project car threads for detailed pictures.

Chris Howards "Turbovan" http://datnet.org/forums/viewtopic.php?f=11&t=3210

Shoeys "SX510 MK2" http://datnet.org/SX-510-SR20DET-510-1800S...-Coupe-t62.html

Mine "GUN16 MK1" http://datnet.org/Gun-16-t8.html

I'm sure you will get some good info from those three and of course the myriad of other project and feature cars on here

Wouldent this weaken the radiator support panel and how would you go with engineering ??

basically wont weaken the rad support cos the intercooler bolts to the rad support and kind of adds rigidity. No problems what so ever for engineering. Would be much more acceptable than a cooler hanging off the front of the car.

and your only cutting minimal metal from the read support.

If you grab a shifter you can bend about 7mm of the radiator support towards the engine bay to bell mouth the opening. it's easy, and it will let heaps more air through. If you take care it really does look factory,


here is where i stole the idea from.

http://datsport.com/Radiator_fitment.html