The front cross
member has to be trimmed to allow access to the intercooler. The illustration
in Photo 3-B below shows the area that needs to be cut. The
best tool to use is an air-operated reciprocating saw as shown in
Photo 3-D, but an electric jig saw will work as well. This cut
will be covered up by the aluminum radiator shield that will be installed
later.
- Mark the area with
a permanent ink pen and double-check all dimensions before cutting.
The cut is going to be at the cusp of the bend of sheet metal shown
in Photo 3-E.
- Using a pilot bit
first and then a 3/8" drill bit, drill two holes on each
corner where you will have a radius as shown in Photo 3-C. This
will help with access for the saw in the turns and improve the appearance
of the cut.
- Using the jig saw or air-operated
saw with a metal cutting blade, cut across the front cross member.
- It is important
that you take a flat file or your Dremel Tool and round off
the edges and corners so you don't cut your hands or arms when working
in this area. Make sure you clean these areas of metal chips since
you would not want them to fall into your Intercooler during installation.
Click on thumbnail
image to see larger image in a new window
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Photo
3-A: Drawing the cut-out |
Photo
3-B: Dimensions for the cut |
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Photo 3-C Pilot hole in corners |
Photo 3-D Cutting opening out |
Photo
3-E: Final cut-out |
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