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Flyin6

Flyin6

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The engine compartment is filling in nicely!

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Is the new radiator going to work?
 
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Today is probably the biggest part of the job. Great thread watching everyday!…Jack
 

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Today is probably the biggest part of the job. Great thread watching everyday!…Jack
You were VERY CORRECT when you made that statement.
You'll see in the next few posts why...
 
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With the painted parts completely cured, it is on to fitting the intercooler.

Here it is just before test fitting:

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It took some more tweaking to get the IC to fit properly. The new aluminum radiator had some extra attachment points for who knows what which I had to cut off. Then I had to remove a smidge more on the passenger side and file it smooth; it went right in.

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With the intercooler in, I played around with some of the rubber couplings to get an idea about their positioning. You don't have much room at all to play with. Especially if attempting to wedge in a radiator twice the size of the factory one.
One of the first things I noticed was those two water/heater lines, which were right in the middle of everything. I secured them to the air pump housing after applying a second layer of abrasion-resistant hose wrap.

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I am going into some detail here in case someone tries to install the SC with a larger radiator as I have chosen to do.

Skipping ahead a little, I wanted to loosely bolt on the air intake bellows to see where I would have to trim the fan assembly

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Then the passenger side intercooler hose assembly was installed for the same reason.

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Ever heard the expression, "Finer than a frog hair?" Well, that minute span is about all you have to work with on this SC setup!
Finally, it was time to fit the fan to see if the thing would work with the larger/thicker radiator. That process had me slide it in, then trim what was interfering. I did that time after time, removing a little bit of material as I went. I spent well over an hour tweaking the final shape.

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BTW, my Jeep has the big 850-watt unit (If I hadn't mentioned that before.

And it fit!!!!!!!!!!!!!!

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You can see just how tightly packed everything is:

At this point, I wrestled the cold side supply pipe into place. I am not done with this yet. I am not "Completely satisfied" with the pipe-to-throttle body alignment. I am thinking the fan assembly is going to give up a little more meat.

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I am going to have to do something with the heater hoses. Placing them in the "factory location" interferes with the supercharger air inlet because of the thicker radiator.
All in all, I am pleased so far, but there is still more to do to score the touchdown on this one.

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