jaluhn83
Full Access Member
Finally got the water side hooked up last week. Haven't gotten a chance to run it under load to see if I can tell the difference but it's got to be good for something.....
The system is based on the frozen boost '600 hp' kit with a type 3 intercooler (12x12.25x4.5", 3" inlet/outlet), a 24x12x1" radiator and I got the Bosch pump for reliability and ease of mounting. All piping is 2 1/2" aluminum fabbed from mandrel bend pieces and using a 2 1/2" to 3" silicone adapter to connect to both sides of the intercooler. The radiator is mounted upside down to make it fit better with a remote filler cap on the top hose. One hose routes over the fan shroud with the filler cap at the center secured to the fan shroud with zip ties, then down and around the driver's side under the radiator support. The other hose routes from the lower radiator port to the pump mounted on the front bumper and then under the passenger side under the radiator support frame to the bottom of the intercooler.
The pump is mounted with the frozen boost mount and band - this works well and there is no issue with noise transmission. I was originally worried that the pump would be noisy without sound isolation but it is in fact very quiet. On a stock rig mounting might be more challenging without the nice winch bumper, but I'd imagine it wouldn't be hard to find a spot on or around the radiator support frame.
The radiator is mounted to the top of the radiator support frame with 2 small tabs welded to the top tank as seen. It sits flush with the front of the top rail and butted up against the bottom of the this rail. I welded a piece of square tube to one side which bears on the lower section of the radiator frame for stability - this is not actually bolted to the radiator frame but provides enough stability to not need to be with the tabs bolted at the top. Originally it was supposed to be bolted, however the location is difficult to access and in retrospect it may be unwise to bolt it to allow flexing of the radiator support with the frame. The stock AC condenser as also replaced with a parallel flow unit (not sure on the size - I can't find the invoice) which is bolted directly to the flange on the radiator (aluminum aftermarket unit). With this setup, there is no modification to the grill required for the intercooler, though I did have to trim about 3/8" in a small area to clear the electric fan. With a stock AC condenser & radiator it might be more difficult to fit.
The actual intercooler sits on the frame rail and up against the battery tray frame. I welded a small plate (~1/4x1") onto the bottom tank which acts as a tab fitting in the gap between the battery tray frame and main frame and secures the bottom of the intercooler. It is not otherwise secured, but is held in place well by the piping. I will eventually fit a bolt or clamp of some sort to secure the top but haven't gotten there yet. The vacuum pump on the rig has been deleted but everything else is stock.
The system is based on the frozen boost '600 hp' kit with a type 3 intercooler (12x12.25x4.5", 3" inlet/outlet), a 24x12x1" radiator and I got the Bosch pump for reliability and ease of mounting. All piping is 2 1/2" aluminum fabbed from mandrel bend pieces and using a 2 1/2" to 3" silicone adapter to connect to both sides of the intercooler. The radiator is mounted upside down to make it fit better with a remote filler cap on the top hose. One hose routes over the fan shroud with the filler cap at the center secured to the fan shroud with zip ties, then down and around the driver's side under the radiator support. The other hose routes from the lower radiator port to the pump mounted on the front bumper and then under the passenger side under the radiator support frame to the bottom of the intercooler.
The pump is mounted with the frozen boost mount and band - this works well and there is no issue with noise transmission. I was originally worried that the pump would be noisy without sound isolation but it is in fact very quiet. On a stock rig mounting might be more challenging without the nice winch bumper, but I'd imagine it wouldn't be hard to find a spot on or around the radiator support frame.
The radiator is mounted to the top of the radiator support frame with 2 small tabs welded to the top tank as seen. It sits flush with the front of the top rail and butted up against the bottom of the this rail. I welded a piece of square tube to one side which bears on the lower section of the radiator frame for stability - this is not actually bolted to the radiator frame but provides enough stability to not need to be with the tabs bolted at the top. Originally it was supposed to be bolted, however the location is difficult to access and in retrospect it may be unwise to bolt it to allow flexing of the radiator support with the frame. The stock AC condenser as also replaced with a parallel flow unit (not sure on the size - I can't find the invoice) which is bolted directly to the flange on the radiator (aluminum aftermarket unit). With this setup, there is no modification to the grill required for the intercooler, though I did have to trim about 3/8" in a small area to clear the electric fan. With a stock AC condenser & radiator it might be more difficult to fit.
The actual intercooler sits on the frame rail and up against the battery tray frame. I welded a small plate (~1/4x1") onto the bottom tank which acts as a tab fitting in the gap between the battery tray frame and main frame and secures the bottom of the intercooler. It is not otherwise secured, but is held in place well by the piping. I will eventually fit a bolt or clamp of some sort to secure the top but haven't gotten there yet. The vacuum pump on the rig has been deleted but everything else is stock.
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