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Old 07-24-2007, 06:18 AM   #5
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Join Date: Sep 2004
Fan#: 12724
Location: Fairmont, WV
What I Drive: Turbo 04 DSG Mach 1

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Day 4

Start time: ~11:00am
End time: ~3:00am

Man this day flew by!
I spent a decent part of the day on mounting the intercooler.
I started today by removing the entire stock air intake so I could move forward with the intercooler plumbing.

I nearly had a heart attack when I saw the crazy shape of the stock MAF. :wallbash:
I also didn't realize it narrowed to 2" either. I just measure one side of it and that was 2.5" (out) and the other side is 3" OD (in)... just too big for my air filter to clamp directly to it.
So I'm standing there holding this MAF, thinking there's NO way I can use this with my pipe selection... and I just ordered my starter tune from LaSota racing!
The 2.5" side of it doesn't clamp at all, but bolts to the air box instead.

I look around and what do I see?? A stock EVO rubber air intake hose!
The filter-side of the EVO hose fits perfectly to the filter-side of my MAF housing!:clap:

There are 2 extra vacuum ports that I'll have to plug, and a much larger hole that I am assuming is for the BPV recirculation line.
At any rate, it will sure work for now! Thanks Scott(evobluebyyou)!

A tip on the stock intake removal:
Loosen these 2 bolts before trying to pull out the intake!
Once those are loose and the hoses are disconnected the upper box part pulls off, exposing the MAF hosing which is bolted to the body.

MAF bolted:

Once I got the stock intake removed I grabbed a 90* 2.5" silicone hose to try on the throttle body - no go!
It's just over 2.5"..
Lo and behold what do I have? A stock EVO elbow that happens to fit perfectly! :thumb2:
I cut it to fit my needs after I took this pic.

The promised pic of the Ford Twilight blue:

My intercooler came with 3 nuts welded at the bottom and top.
I had to grind down the top ones in order for it to fit properly:

After a trip to the hardware store for some bolts (in the wife's car) I mounted the intercooler.
My brackets are made from stock EVO intercooler pipe brackets!
*warning* If you ever grind/cut aluminum do it outside if you can!
Aluminum goes airborne more than steel, but mainly it "shaves" off in little tiny slivers that get EVERYWHERE!!
Definitely not good for the lungs, or the freshly poured Pepsi Jazz. Doh!

I took care of the Power Steering line issue by unhooking it from the 2 plastic brackets in front of the radiator and pushing it up onto the "ledge" above it.
Then I zip-tied it to a wire loom already present there.

Driver side:
(tie is red)

Passenger side:
(tie is red)

Moving on to the upper intercooler pipe..
I didn't get to the lower pipe today. I started laying stuff out though.

Gen 1 bpv mount welded:

Full shot of upper IC pipe:
It's also painted twilight blue now.
Hole is for the boost gauge bung.

I bought a kit from Advance Auto Parts for $5 or $6 for my boost gauge.
It has a male 1/8" NPT fitting at the end.
I happened to have an extra 1/4" NPT to 1/8" NPT adapter, so I made a bung out of it.
I drilled a 1/2" hole in the IC pipe, cleaned it, applied a liberal amount of Ultra Copper sealant and threaded it in!
I think it should work nicely!

I will be out of town the next 3 days!
'04 Mach 1. Built. Turbo. 667whp/631wtq
'06 Focus. Built. Turbo. WMI. (sold)
'03 Mach 1 : 12.61 @ 106.59 (sold)

Last edited by sutyak; 09-05-2007 at 10:01 AM.
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