My new intercooler setup (w/many pics) - Ford Focus Forum, Ford Focus ST Forum, Ford Focus RS Forum
Ford Focus Forum
HomeContact UsAbout UsGalleryDiscussion ForumsMarketplace


Go Back   Ford Focus Forum, Ford Focus ST Forum, Ford Focus RS Forum > Ford Focus Tech Discussions > General Forced Induction

General Forced Induction The place to chat about turbochargers, superchargers nitrous systems and custom engine fabrications.

Search This Forum | Image Search | Advanced Search    
FocusFest FocusFanatics Merchandise

Reply
 
LinkBack Thread Tools Display Modes
Old 04-14-2010, 04:10 PM   #1
Focus Enthusiast
 
Join Date: Sep 2008
Fan#: 59125
Location: Oregon City, OR
What I Drive: 2003 Turbo 2.3l ZX3

Posts: 50
FF Reputation: 1 GreggPDX Good Standing Member
Buy-Sell-Trade Rating: (2)
My new intercooler setup (w/many pics)

I just finished fabbing my new intercooler setup, so I wanted to share my experience and some pics. My current setup is a 2003 ZX3 with a Duratec 2.3 and the FSWerks Stage 1 (non-intercooled) turbo kit. I decided to add my own intercooler for several reasons, but the biggest was the custom design needed to fit behind the Euro bumper. My goal was to add the biggest/best intercooler I could fit with the least amount of cutting into the bumper cover.

It would be almost impossible to fit an intercooler without some cutting, but I wanted to minimize it, and I'm very pleased with the results. The intercooler I selected is a Garrett-core unit with an 18"x6.5"x3" core and 24" overall length. It's rated to 400hp, and I believe it will support my power goals for the foreseeable future.

To make it fit, I had to relocate the power steering cooler, and trim the bottom part of the bumper cover. I also moved the horn. In the pictures you’ll see that the charge pipes on the inlet side of the intercooler have to make several turns to get clear of the bumper. All this extra fitting is because the Euro bumper is tucked much closer to the front of the car, and the fog lights reduce clearance dramatically on the sides.

I also notched the crash bar to tuck the intercooler up a bit higher. Again, this was for clearance, and to maximize the exposed area on the front of the intercooler.

Finally, the charge pipe is 2” from the turbo to the intercooler, and 2.5” from the intercooler to the TB. It’s mild steel and I MIG welded it (.024 wire and C25 gas).


First Pic is showing the intecooler fitment after I notched the bumper beam:



Another test-fit picture:



Another pic with intercooler bolted up, you'll notice the power steering cooler on top, it still needs a mounting bracket fabbed:



Here it is with the bumper cover installed:




Another view of the bumper cover:



Here is a pic of the inlet side mocked-up before welding, the blue tape is holding the pieces together:



Here is the inlet side installed, this illustrates how tight the area is where the piping runs:



Another view of the inlet, you'll notice the stage 1 piping hanging right below:



Here is the outlet side mocked-up and tacked:



and here is the outlet pipe installed:



Another view of the outlet pipe after it was tacked:



Here are both pipes after welding, you'll notice the IAT bung added as well, and bead welds on the ends:



Another view of the same:



I just picked up the pipes for the powder-coater today, so I'll be adding some pictures of the final result soon. This weekend I'll install everything, then it's time for the boost controller!


__________________
2003 Twilight Blue ZX3, 2.3l, FS turbo kit with custom intercooler, 3" exhaust, Cosworth intake manifold, SVT brakes, Koni coilovers, EAP wheels, ST170 front end.
GreggPDX is offline  
    Reply With Quote Quick reply to this message
Sponsored Links
Advertisement
 
Old 04-14-2010, 04:19 PM   #2
Focus Addict
 
ISLAND FOCUS's Avatar
 
Join Date: May 2009
Fan#: 64793
Location: canada, United States
What I Drive: 2002 Focus SE sedan

Posts: 674
Points 4,603, Level 43
Points: 4,603, Level: 43 Points: 4,603, Level: 43 Points: 4,603, Level: 43
Level Up 27% Completed
Level up: 27% Level up: 27% Level up: 27%
Forum Activity 2%
Activity: 2% Activity: 2% Activity: 2%
FF Reputation: 4 ISLAND FOCUS Good Standing Member
Buy-Sell-Trade Rating: (26)
Is the power steering cooler hard to install?
ISLAND FOCUS is offline  
    Reply With Quote Quick reply to this message
Old 04-14-2010, 05:03 PM   #3
Bewst Anyone!!!
 
pitchedblack04's Avatar
 
Join Date: Feb 2009
Fan#: 62993
Location: louisville, KY
What I Drive: 2004 turbo'd svt

Posts: 1,871
Points 3,266, Level 35
Points: 3,266, Level: 35 Points: 3,266, Level: 35 Points: 3,266, Level: 35
Level Up 44% Completed
Level up: 44% Level up: 44% Level up: 44%
Forum Activity 0%
Activity: 0% Activity: 0% Activity: 0%
FF Reputation: 7 pitchedblack04 Good Standing Member
Buy-Sell-Trade Rating: (3)
Awesome man. Looks great.
__________________
Car is for sale. Pm me for details.
pitchedblack04 is offline  
    Reply With Quote Quick reply to this message
Old 04-14-2010, 05:08 PM   #4
I Fab Too Much
 
Roushturboedzx3's Avatar
 
Join Date: Jan 2007
Fan#: 42814
Location: CLearwater, FL
What I Drive: 2002 Liquid Gray ZX3

Posts: 4,739
Points 15,008, Level 79
Points: 15,008, Level: 79 Points: 15,008, Level: 79 Points: 15,008, Level: 79
Level Up 32% Completed
Level up: 32% Level up: 32% Level up: 32%
Forum Activity 0%
Activity: 0% Activity: 0% Activity: 0%
FF Reputation: 20 Roushturboedzx3 Great Standing Member
Buy-Sell-Trade Rating: (18)
Honestly man that looks really nice i like how all the bends flow looks very top notch, you pretty good at mig welding too.
__________________
New: 2012 Mustang GT premium
SOLD:RACE GAS 602whp 501tq Pump Gas SAE 454whp
Garrett GT3582r, Topmount, built motor, Ported head,Tuned by Fernando@RacingPartsSolution
I may not be the baddest, but the baddest dont Fu** with me
Roushturboedzx3 is offline  
    Reply With Quote Quick reply to this message
Old 04-15-2010, 11:23 AM   #5
Focus Enthusiast
 
Join Date: Sep 2008
Fan#: 59125
Location: Oregon City, OR
What I Drive: 2003 Turbo 2.3l ZX3

Posts: 50
FF Reputation: 1 GreggPDX Good Standing Member
Buy-Sell-Trade Rating: (2)
Quote:
Originally Posted by ISLAND FOCUS View Post
Is the power steering cooler hard to install?
Not really, I just unhooked the old cooler line from the reservoir and cut the other side just in front of the transmission. That allowed me to remove the old cooler, then I spliced a new rubber line where I cut, ran it to the new cooler, then from there back to the reservoir again. The lines generally follow the original path, just up higher.

The cooler I used was from CXRacing: Link
__________________
2003 Twilight Blue ZX3, 2.3l, FS turbo kit with custom intercooler, 3" exhaust, Cosworth intake manifold, SVT brakes, Koni coilovers, EAP wheels, ST170 front end.
GreggPDX is offline  
    Reply With Quote Quick reply to this message
Old 04-15-2010, 11:26 AM   #6
Focus Enthusiast
 
Join Date: Sep 2008
Fan#: 59125
Location: Oregon City, OR
What I Drive: 2003 Turbo 2.3l ZX3

Posts: 50
FF Reputation: 1 GreggPDX Good Standing Member
Buy-Sell-Trade Rating: (2)
Thanks to everyone for the kind words, I spent a lot of time on this project, mostly test fitting everything over and over again. I removed/replaced the bumper cover at least 10 times while I was cutting it, and fabbing the pipes was a similar process of test-fit, cut a little, test-fit, repeat about 15 times.

I'd estimate around 50 hours of work in total, but I definitely took my time. I'm also not a great welder, so I spent a lot of time making sure the pipes fit very tight before I welded them. Then it was a bunch of 1" welds, working my way around making sure the welds were solid and trying very hard not to burn through.

Here are some pics of the finished product, powder coated black wrinkle:





And here is my simple little boost controller that is going to make the intercooler worth the effort. I am currently running off the wastegate only at 8psi, so with this I intend to work the boost up to at least 12psi. I still need to get logging and a wideband setup before I really start pushing it.



The MBC is from this guy: http://www.joepmbc.com and they have a good reputation with the DSM crowd. I got the "soft" spring version which only allows +7 psi, but finer control.

My plan is to get all this stuff installed this weekend. I'll post some more pics when it's all done.
__________________
2003 Twilight Blue ZX3, 2.3l, FS turbo kit with custom intercooler, 3" exhaust, Cosworth intake manifold, SVT brakes, Koni coilovers, EAP wheels, ST170 front end.
GreggPDX is offline  
    Reply With Quote Quick reply to this message
Old 04-15-2010, 11:28 AM   #7
RB25 = Amazing
 
SVTflyer03's Avatar
 
Join Date: Jan 2009
Fan#: 62344
Location: Columbia,, SC
What I Drive: 2003 Infra Red SVT ZX5, 1991 240sx

Posts: 5,259
FF Reputation: 5 SVTflyer03 Good Standing Member
Buy-Sell-Trade Rating: (1)
Wow, looks really good man. Good work!
__________________
Moderator for your Buy - Sell - Trade, General Chat, and Showroom forums

SVTf 5-door #892 out of about 2200

Hi
SVTflyer03 is offline  
    Reply With Quote Quick reply to this message
Old 04-15-2010, 11:39 AM   #8
Proudly Daily Driven
 
mtadd162's Avatar
 
Join Date: Jun 2007
Fan#: 47890
Location: Massachusetts, Afghanistan
What I Drive: 2005 Focus ST

Posts: 2,255
Points 5,921, Level 49
Points: 5,921, Level: 49 Points: 5,921, Level: 49 Points: 5,921, Level: 49
Level Up 86% Completed
Level up: 86% Level up: 86% Level up: 86%
Forum Activity 0%
Activity: 0% Activity: 0% Activity: 0%
FF Reputation: 9 mtadd162 Good Standing Member
Buy-Sell-Trade Rating: (5)
badass man...nice work
__________________
05 Focus ST-Sold but missed
-ST Crew #73 N/A FTW!
Feb. 09' ROTM
SSR - Silver Sedan Revolution Member #1
Cams Installed, great made my car into a VTAK
mtadd162 is offline  
    Reply With Quote Quick reply to this message
Old 04-15-2010, 11:35 PM   #9
Fins Up!
 
Turbo Turtle's Avatar
 
Join Date: Mar 2006
Fan#: 32772
Location: Calera, AL
What I Drive: STi & Miata

Posts: 4,842
Points 21,726, Level 92
Points: 21,726, Level: 92 Points: 21,726, Level: 92 Points: 21,726, Level: 92
Level Up 38% Completed
Level up: 38% Level up: 38% Level up: 38%
Forum Activity 0%
Activity: 0% Activity: 0% Activity: 0%
FF Reputation: 55 Turbo Turtle Excellent Standing Member
Buy-Sell-Trade Rating: (25)
looks good nice work
__________________
Turbo Turtle Garage
Zetec and Duratec Turbo kits, engine building

turboturtlegarage.com
facebook.com/TurboTurtleGarage
TurboTurtleFab@gmail.com
Turbo Turtle is offline  
    Reply With Quote Quick reply to this message
Reply

Bookmarks & Social Networks

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the Ford Focus Forum, Ford Focus ST Forum, Ford Focus RS Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:
What I Drive
Year, color, and model of your car. Example: 2003 Pitch Black ZX3
Name
Your real name.
City
State
Country
Insurance
Please select your insurance company (Optional)

Log-in

Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools
Display Modes

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On



All times are GMT -5. The time now is 12:07 PM.


Copyright 2002-2015 FocusFanatics.com. All Rights Reserved : Privacy Policy : Advertise Information

Focus Fanatics Ford Focus Forum offers many fun ways for you to engage with other Ford Focus Owners from across the world. Whether it be about the aftermarket performance modifications, technical how-to's, European tuned suspension or awesome fuel economy similar to the Mazda CX-3, Audi S3, Mazda MX-5 Miata and Acura TLX. You can find all Ford Focus, Focus ST and Focus RS related information here. Join our Ford Focus discussion forums and chat with local Focus enthusiasts in your area. If you own other makes have a look at Challenger Hellcat Forum, Charger Hellcat Forum, Cadillac ATS-V Forum, Cadillac ATS Forum, Cadillac CTS-V Forum, Lexus RC-F Forum, Lexus GS-F Forum, Mercedes GLA Forum, Mercedes GLE Forum, Civic Type-R Forum and Volvo XC90 Forum.





Search Engine Optimization by vBSEO 3.6.1