These are pictures of an intercooler that was just installed . It is a ZZ Performance short stack intercooler that is 1" thick. It is easier to install than the standard 2" tall model as deck lid clearance is no issue. The installation requires mounting an electric water pump, front heat exchanger and the intercooler hoses that run the length of the car. Here are the pics with my comments:
First you fabricate and mount two brackets to hold the heat exchanger in place. Here we are using a 3 1/2 deep 26" wide unit made by Frozen Boost. Its about the largest Heat exchanger that you can fit under the facia. The mounts are 1" w x 1/4" steel and they are welded in place. The coolant exit will be from the top to prevent cavitation. The HE will be in a direct air stream and I don't believe that fans will be needed.
Then you mount the pump on the side where coolant exits the heat exchanger core. This is a FloJet pump that is used for RV water supply applications. It is mounted in the driver side wheel well. Notice that the horn had to be moved but it was a good opportunity to replace the low sounding GM unit with a Fiamm horn.
After running hoses to the engine compartment its time to remove the supercharger and install the IC core. Its a tricky process but if you do the cross torque tightening in sequence you can get a good seal with no binding of the supercharger. This is a test fit
And here is how the gasket sits in place. We are using Gorlock gaskets for a tight seal
Now its time to mount the supercharger over the IC . Torque on the mounting bolts is 18ft lbs and it MUST be done in small steps
Here's how the IC looks under the supercharger
Then its a simple matter of reinstalling the fuel rail, plugging the TPS, MAF, MAP/ IAT sensors back in, hooking up the hoses, wiring the pump, re-aranging the harness etc. ZZ recommends a 33% dexcool/distilled water mixture. I'll get some additional pics of the finished install up this week.
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" THE BLACK PARALYZER" -87GT 3800SC Series III engine, 3.4" Pulley, N* TB, LS1 MAF, Flotech Exhaust Autolite 104's Custom CAI 4T65eHD w. custom axles, HP Tuners VCM Suite.
"THE COLUSSUS" 87GT - ALL OUT 3.4L Turbocharged engine, Garrett Hybrid Turbo, MSD ign., modified TH125H
" ON THE LOOSE WITHOUT THE JUICE " [This message has been edited by Dennis LaGrua (edited 08-13-2011).]