Whew! We're getting close, gang. There have been some pitfalls and holdups, but the SE-R is now in the final stages of the turbo install. I finally had a day to do some work after returning from vacation. Many thanks to Serban (FAST91SER) for hosting the pics again. Here's the results...

http://garnet.acns.fsu.edu/~sgg8661/greg/frontic.jpg
When Wednesday morning rolled around, I began work on the passenger side of the intercooler piping. While on vacation, I had ordered up a 180-degree mandrel bend from Summit, hoping to cut it into two 90-degree units. It actually worked out perfectly, as you'll see.

http://garnet.acns.fsu.edu/~sgg8661/greg/icpipes1.jpg
Here's the pipe coming out of the IC. That is *exactly* 1/2 of a 180-degree mandrel bend with equal-length legs. $17 at Summit. It fits perfectly.

http://garnet.acns.fsu.edu/~sgg8661/greg/icpipes2.jpg
That pipe connects to a shortened 45-degree mandrel bend, which shoots straight up into the engine compartment. It is very easy to expand the hole in the fenderwell, as the metal is very thin. I used a pair of vice grips and just pulled the metal away.

http://garnet.acns.fsu.edu/~sgg8661/greg/icpipes3.jpg
And here's that hole I just mentioned. Took 20 seconds to enlarge that hole with vice grips.

http://garnet.acns.fsu.edu/~sgg8661/greg/icpipes4.jpg
And here's where the other half of that 180-degree mandrel bend went to. :D Again, it fits *perfectly*. You'll notice that, yes, I have removed the AC from my car. It seemed like the right thing to do, as... I never use it....it needed a recharge and conversion over to R134 refrigerant....and it gets in the way of the turbo outlet pipe.

http://garnet.acns.fsu.edu/~sgg8661/greg/frontic2.jpg
And at the end of the day, here's how my SE-R looked. Like a car again. Notice I cut a hole in the driver side of the front bumper, to clear the IC piping. Truth be told....that front bumper cover's days are numbered. It's scarred up from a fender-bender I had 3 years ago, plus the bugs have taken their toll. So, it was easier to just cut the material away than go back in and re-engineer my IC piping (read: hack with a saw). That bumper will be replaced later on this summer. I kinda' like the look. It's sort of Ghetto Tuner-ish.

http://garnet.acns.fsu.edu/~sgg8661/greg/frontpipe.jpg
And here's what the hole looks like. It's small, really. And, it gives unsuspecting prey an idea of what's lurking under the hood.

There you go, my Day 6 of turbo-wrangling. On Thursday, I anticipate firing the car up for the first time. I have to cut the SR20Development downpipe apart (the one that didn't fit), so that I can use the 'down' part with the O2 sensor in it to drive over to the exhaust shop. Keep your fingers crossed.

Thats what I wanted to see! :)

Hey looks good! , for the ic pipe hole in the bumper just paint the ic pipe black in that spot. NO will will notice unless they look.

looks good :)

Hey Greg, what did you do with the coolant container? Does it fit under the IC piping?

Originally posted by blackb13
Hey Greg, what did you do with the coolant container? Does it fit under the IC piping?

We'll find out on Thursday, I imagine. ;)
Stay tuned...

It should only need to be rotated 90-degrees, and a longer piece of hose purchased to reach over to it.

Looks tight Greg!!!

Screw the sleeper look!!!;) :D

Greg, maybe this has been asked before, but where did you get those blue coupler band thingies that hold your IC pipes together?

Those couplers are actually called Purosil turbo hose. I bought a 3-foot long 'stick' of it. Baker Precision ( www.bakerprecision.com ) sells Purosil, too. I bought mine from a guy on eBay who bought a case of the stuff at a Lost Freight auction.
If you go to eBay and do a search for 'Purosil' or 'turbo hose', you'll probably find him. He sells one stick per week, and had plenty left in February when I bought mine.

BTW...Purosil retails for about $23 per foot.

-GP-

Greg, if you get the time can post a complete list of what bends you've used and in what order. I think I've got it from the pics and your notes, but just want to make sure. Also, I assume it wouldn't be too hard to work it without having to cut the bumper cover, yea? Thanks.

I must say that your IC piping is great. I love seeing people use homemade piping. Now if you could have only made your intercooler from scratch :)

Best writeup ever ! The details are great for anyone doing a turbo install.

Start that baby up !

Just curious what kind of intercooler is that? I dont wanna drop $800 USD on an intercooler. I wanted to find something small and temporary as well. how much did you pay for it?
Have you ever seen a Starion intercooler. Im curious to how that looks

Calum--
The bends I've used are listed below. Notice that the front pipes can easily be cut to accomodate the Forge intercooler when it arrives next month. :D I'll just cut about 10" out of each pipe, and voila', it should fit in there...
- (1) 180-degree mandrel bend, equal length legs. I have the part # from Summit, should you need it. $17.
-(3-4) 90-degree bends.
- (2) 45-degree bends.

That should get you where you want to be, and maybe have a bend or two left over.

Note that you can replace 2 of the 90-degree bends listed with another 180-degree bend, if you'd like. Probably a buck or two cheaper that way.

CanadianG--
The intercooler that's on there now is one from a Nissan Bluebird. It is small. However, it is only there to get the car up and running consistently. By that time...a Forge Motorsports intercooler will be in my possession. :)
You don't have to drop $800USD on an intercooler. Just send Louis Anaya (TurbochargedSER here on the forum) a PM or email, and he'll hook you up with the Forge Motorsports intercooler we did the group buy on. The price has gone up a little, but nowhere NEAR $800 USD. Ask Calum about that intercooler. It is top-notch.

-GP-

damn greg.. that shhh looks PHAT!! can i borrow your car my dear old friend...lol..

nice job..

Having it in my hands for a few days that forge piece looks pretty. Dont know numbers on it but the craftsmanship on it is top notch. I havent seen welds that pretty in a long long time. only thing i said about it was that it could use more fins between its ribs but not like its skimping either. I cant wait to see it go in and see numbers on it. Oh yea and that i get to drive the black rascal from time to time :D

Just a suggestion but why not paint the IC pipe where you cut the bumper black. Makes it not stick out so much. You did a good job though.

-Kris

Originally posted by SERprise In WV
You don't have to drop $800USD on an intercooler. Just send Louis Anaya (TurbochargedSER here on the forum) a PM or email, and he'll hook you up with the Forge Motorsports intercooler we did the group buy on. The price has gone up a little, but nowhere NEAR $800 USD. Ask Calum about that intercooler. It is top-notch.

I highly recomend the Forge unit. It is *very* high quality, it shows that these guys take pride in their work.

These pics really don't do it justice, its much nicer in person. Also, its hard to get a good frame of reference as to how large it is in them.

For what these things cost, they are a steal. I'll match 'em against a spearco or HKS of similair size anyday.

http://gemini.tntech.edu/~cjj6558/inbox.jpg

http://gemini.tntech.edu/~cjj6558/top.jpg

Sorry Greg I was quoting the Hotshot kit with the piping. I dont mind the custom piping. Just as long as I can find a cheap intercooler for now. Im kinda tight with money and will buy a better intercooler next summer. I too just want to get the car up and running

I think I have to add my .02 cents to this Forge debate... When I recieved this Intercooler... I thought I was dreaming... Because I have never seen welds so professional in my 22 years of living that its sick... The brackets they put on the unit were perfect for me to make L brackets with and my car already had bolt holes in the steel support beams to bolt the IC to the car... I will take pics for you guys this weekend... needless to say, with the IC where it is and my custom brackets I only had to trim very small portions of the bumper, no "flywheel to bumper support or hammer to bumper support or any of that mess" :D I used brake cleaner to clean off the "leak test ink" and it came out beautiful... I highly recommend their piece anyday... (I've even hooked up my friend's Z24 turbo club with the Forge Units) :p (We still kill them of course) :D