DIY Frontmount using the Forge intercooler
Notes
1) When I installed my (secondhand) Forge intercooler I generally followed these instructions but my fitting differed in many respects from these pages. The most significant change was to reinforce the J-pipe so that engine vibrations were not carried solely by the 3 compressor bolts. Many thanks are due to Forge for this upgrade based on my specification. You may never feel the need to make this mod yourself, I'm very happy with the end result.
2) Although these instructions are for the Forge kit, they are quite old. For example, the latest Forge intercooler kit has polished stainless steel thin wall pipes throughout, rather than the thick wall alloy pipes shown. Also, the kit contains proper, custom made brackets and an unique one-piece Samco pipe to fit the intercooler outlet, replacing 3 Samco pipes and two alloy tubes.
3) I only used the angle grinder to cut away the bumper reinforcement bar (in the two places mentioned). Other cuts can easily be made with tin snips e.g., the metal around the headlamp mounting is very thin. After snipping, I rolled the edge so as to avoid long-term damage to the Samco.
4) I also "padded" the Samco where it rests against the chassis in one or two places, again avoiding damage caused by rubbing.
