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Air to Air Intercooler How-To

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  • Air to Air Intercooler How-To

    DIY FMIC Parts

    I've recieved quite a few requests for the parts needed to make your own A/A FMIC so I put
    together this little list of items I used.

    First off, doing the setup I did required me to remove the AC, trim the radiator support a bit,
    and install an electric fan.

    The core is Sized 24"X12"X3" with an overall Size 31"x12"x3"using 3" Inlet & Outlet, cost to me shipped was 128.98 from Just-Intercoolers on ebay. It came with mounting brackets as well.


    Piping is 3.0" Polished Alumuinum , I bought the kit on ebay for $146.99 shipped from the seller Just-Intercoolers, the kit came with pipe and choice of silicone it came with standard clamps but I replaced them with much better T-Bolt style clamps.


    Pipe: total 8 pieces
    1x 75 3.0"
    1x U Bend 3.0"
    3x 90 3.0"
    3x Straight 3.0"
    1x U Bend 3.0"

    I remember having leftover pipe, next time I look at my engine I'll note what actual pipes I used.

    I bought the T-Bolt Clamps and certain hoses from www.siliconeintakes.com and needed the following:

    17x 3.0" @ $2.60 each
    1x 4.0"
    1x 2.0"
    Cost of clamps = $49.40

    Silicone Hoses needed:
    1x Silicone Reducer, 3.0" to 2.0" - $12.99
    1x Silicone Reducer, 4.0" to 3.0" - $12.99
    3x 3.0" Silicone 90 Elbow - $50.97
    Total Cost of Silicone Hoses: 76.95

    Electric Fan: Perma-Cool 16" 2950CFM - $115.99 at Summitracing.com

    Completed Look:



    Total Cost: $518.31 - of course your cost might be a little different on how you do it.
    -Pete

  • #2
    Re: Air to Air Intercooler How-To

    Very nice set up for low cost. Good wite up also. I vote for vault.
    Dameon Barnhart
    Sy 1664
    13.006 @ 102.04 w/ 1.896 60'
    I can break 100 MPH

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    • #3
      Re: Air to Air Intercooler How-To

      That looks clean... Any pics of the underneath where the I/C pipes route??
      92 Typhoon #721 3" exhaust with Magnafow muffler, K&N drop in for now.
      Compustar 2 way alarm w/auto start & built in Turbo Timer. GPS Tracking System

      Typhoon Sticker Kits Available. PM me for more details

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      • #4
        Re: Air to Air Intercooler How-To

        I'm uploading a bunch more pics to www.epixpc.com/syty/a2a
        -Pete

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        • #5
          Re: Air to Air Intercooler How-To

          did you notice a drop in temps ove the w2a?
          any hp increase in this?
          This is my Syclone. There are many like it, but this one is mine. Without my Syclone I am nothing. Without me, my Syclone is nothing..............

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          • #6
            Re: Air to Air Intercooler How-To

            Doesn't mounting your transmission cooler with the outlets at the bottom cause air to get trapped in there?

            1991 Syclone 2241 - 87k miles
            2006 Cobalt SS
            2006 Trailblazer SS AWD
            RIP 6/10/08 1998 Saturn SL2 #1 - 236,456 miles
            RIP 12/12/13 1998 Saturn SL2 #2 - 315,000 miles

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            • #7
              Re: Air to Air Intercooler How-To

              That looks great....I am curious at how effective it is also ---
              90' ZR-1 Corvette LPE #699
              01' Dodge Viper GTS
              06' Jeep Grand Cherokee SRT8
              03' Harley Edition f-150 #577

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              • #8
                Re: Air to Air Intercooler How-To

                hatrik, that was just for mock up/idea, the tranny cooler ended up being mounted where the stock lower IC was in the stock bracket and using a spal fan
                Last edited by epix; 03-23-2007, 05:02 PM.
                -Pete

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                • #9
                  Re: Air to Air Intercooler How-To

                  question... inquiring minds need to know..

                  what is the rule of thumb for sizing intercoolers ?

                  87 Fiero GT 5sp with Vortec L35 4300 Turbocharged V6
                  Bully Stage 2 clutch
                  Syclone intake manifold and engine management with Moates adapter
                  Air/water intercooler and Devil's Own progressive water/alky injection
                  Walboro fuel pump and Johnston Intercooler pump
                  LM1 wideband and 3" stainless exhaust system with an ITS minegate
                  TO4B H3 turbo on homemade exhaust manifolds
                  S10 caliper conversion.

                  Murphy's Constant Matter will be damaged in direct proportion to its value
                  Murphy's Law of Thermodynamics Things get worse under pressure.
                  Arthur C. Clarke "Any significantly advanced technology is indistinguishable from magic"

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                  • #10
                    Re: Air to Air Intercooler How-To

                    Originally posted by vortecfiero
                    question... inquiring minds need to know..
                    what is the rule of thumb for sizing intercoolers ?
                    not sure, I bought this book last spring and read it before I bought my turbo and IC
                    http://www.amazon.com/Maximum-Boost-.../dp/0837601606 has lots of good info

                    This probably isn't as good and engineered as a RPM kit but its nearly 1/2 the price as well.
                    -Pete

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                    • #11
                      Re: Air to Air Intercooler How-To

                      i also noticed the turbotime and rpm units use a smaller core
                      This is my Syclone. There are many like it, but this one is mine. Without my Syclone I am nothing. Without me, my Syclone is nothing..............

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                      • #12
                        Re: Air to Air Intercooler How-To

                        Originally posted by Ryda85
                        i also noticed the turbotime and rpm units use a smaller core
                        I think thats to improve pressure loss and efficiency levels ---
                        90' ZR-1 Corvette LPE #699
                        01' Dodge Viper GTS
                        06' Jeep Grand Cherokee SRT8
                        03' Harley Edition f-150 #577

                        Comment


                        • #13
                          Re: Air to Air Intercooler How-To

                          Just a little info. I recently did an air/air setup to a fellow sytyer from Tampa a few weeks ago. I used a "godspeed" air/air core off of ebay for $250 new and the quality was very good. The inlet/outlet are on the same side and are 3". The core was 3.5" I believe. Total for the core, piping, silicone hose, and t-clamps were under $500. I tig'd him up some intercooler pipes and also installed an alky injection kit. I ended up fabbing a meth tank out of 18gauge stainless complete with a sump, -8 feed, billet cap, and a vent. The tank bolted right up to where his stock windshield wiper fluid tank was. If someone can host them for me, i'll share some pics.

                          later
                          Jordan

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                          • #14
                            Re: Air to Air Intercooler How-To

                            I like the sound of the meth kit where the wiper fluid should be !!! PM sent about hosting pics ---
                            90' ZR-1 Corvette LPE #699
                            01' Dodge Viper GTS
                            06' Jeep Grand Cherokee SRT8
                            03' Harley Edition f-150 #577

                            Comment


                            • #15
                              Re: Air to Air Intercooler How-To

                              good shit I need alot of trial and error before i do it
                              a few people have asked about horsepower loss or gains???
                              what about turbo sound did it change (wistle) whay about lag???
                              65 COVAIR mid.engine 350 stroked and blown
                              04 ESCLADE EXT AWD DUMPED ON 26s
                              91 SY #0500 (stock)
                              93 TY BLK/BLK #1358 GT-35R LOTS OF GOODIES
                              MAITAI

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