Forced Induction Supercharger/Turbocharger

Cutting the honeycomb for an intercooler...

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Old May 3, 2007 | 10:00 AM
  #1  
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Cutting the honeycomb for an intercooler...

When you guys have cut the honeycomb 'neath the front bumper cover, what did you use to cut the stuff? A sawzall? Cutoff wheel? Hacksaw? Cutting pliers? I'm getting ready to install my OBX intercooler and I want to get the tools, etc all set up beside the front of the car to minimize running around.
Thanks!
Old May 3, 2007 | 11:23 AM
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Cut off wheel and/or a sawzall works wonders!

-B
Old May 3, 2007 | 11:38 AM
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Thanks!

Originally Posted by blown383
Cut off wheel and/or a sawzall works wonders!

-B
Old May 3, 2007 | 12:36 PM
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Here are some pics for your reference.





-B
Old May 3, 2007 | 01:14 PM
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Perfect! Thanks! Looks pretty straight forward. On the actual bumper cover, did you remove that black plastic inset area (where the stock front license plate box used to be) so that the incoming air could directly encounter the intercooler?
Originally Posted by blown383
Here are some pics for your reference.


-B
Old May 3, 2007 | 03:30 PM
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Originally Posted by DirtyDaveW
Perfect! Thanks! Looks pretty straight forward. On the actual bumper cover, did you remove that black plastic inset area (where the stock front license plate box used to be) so that the incoming air could directly encounter the intercooler?
Yup... here is an old picture its now tucked up higher so I had to move the intercooler forward a little and make a new bracket for it.



I plan on cutting out the rest of the black area out and adding a black grill to the front of the car. I'm going to add the red bowtie on top of the mesh grill.

-B
Old May 3, 2007 | 03:38 PM
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Looks good. I just removed the whole support, but I don't plan on driving the car much.
Old May 3, 2007 | 05:07 PM
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Sounds like a great idea. I like the look you already have but the one you envision sounds even better Thanks again for the excellent pictures. Did you also use the Sawzall for this plastic as well?

Originally Posted by blown383
Yup... here is an old picture its now tucked up higher so I had to move the intercooler forward a little and make a new bracket for it.



I plan on cutting out the rest of the black area out and adding a black grill to the front of the car. I'm going to add the red bowtie on top of the mesh grill.

-B
Old May 4, 2007 | 01:34 AM
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Originally Posted by DirtyDaveW
Sounds like a great idea. I like the look you already have but the one you envision sounds even better Thanks again for the excellent pictures. Did you also use the Sawzall for this plastic as well?
Thanks for the kind words! I just used a utility knife with a new blade and it cut right through it like butter. I didn't want to use the cut off wheel or sawzall on the bumper since it was very ackward to try and get those tools in there. A dremel would also work wonders in there. Good luck!

-B
Old May 5, 2007 | 06:33 PM
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Originally Posted by blown383
Thanks for the kind words! I just used a utility knife with a new blade and it cut right through it like butter. I didn't want to use the cut off wheel or sawzall on the bumper since it was very ackward to try and get those tools in there. A dremel would also work wonders in there. Good luck!

-B
Hey B!

Post some pictures of the mesh grill when you get that done. That is the exact thing I was planning on doing with the bowtie, but over a painted bar-style grill. I'd be interested to see how the mesh looks also.
Old May 5, 2007 | 07:30 PM
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Originally Posted by snorkelface
Hey B!

Post some pictures of the mesh grill when you get that done. That is the exact thing I was planning on doing with the bowtie, but over a painted bar-style grill. I'd be interested to see how the mesh looks also.
No problem! How is your car coming along? I haven't spoken to you in months!

-B
Old May 5, 2007 | 07:31 PM
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Originally Posted by blown383
No problem! How is your car coming along? I haven't spoken to you in months!

-B
All of the parts are FINALLY in, and it's starting being put back together next week. They expect it to take about 3 weeks with someone working full time on it including the tuning.

How about you? You should be up and running by now.
Old May 5, 2007 | 07:34 PM
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I thought I would be up and running but Im working 2 jobs now so no time to work on the car! Also the machine shop that honed my big block hub took off too much material for my crank so now its no longer a press fit but a slip fit. I have to order a new one.... till then its holding up my entire project.


-B
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