Sleeps 4 at 120

So I'm putting in a '91 20v intercooler into my '87 5k. You have to replace the crossmember to make the inlet tube of the intercooler fit.

I took the bumper off, and the stock crossmember seems to support the underside of the headlamps and attach to some other parts too. The '91 cross member is a completely different beast, and just runs between the two bumber posts. I am thinking of cutting the stock crossmember where it hits the bumper posts.

Any suggestions, comments, or BTDT?

birdmanmt

i just cut those tab thingys that attach the stock crossmount to the other stuff. No adverse effects that i'm aware of. then the 200 one just bolts in. nice change! or you can just notch your stock one and leave it there.

Sleeps 4 at 120

...the turbo outlet to the intercooler inlet? The stock hose isn't oriented right, and the '91 is several inches too long.

birdmanmt

i used the 91 crossover pipe and had it cut and rewelded at a different angle on the end near the turbo. then i had to make a pipe that connected the turbo outlet to the crossover with some silicone transition pieces with t-clamps everywhere. The pipe to go from turbo to crossover is easiest gotten by bending a wire to the shape that will work and then going to any exhaust shop and having them manderl bend you a pipe that matches. You may have to bend, test fit, bend again. The shop i used got it right on the first try thank god! You can use two pieces of wire as the outsides' of the pipe as well ot get a better feel for space. It takes some work to this one just right.

hth

SteveAngry

<center><img src="http://pictureposter.audiworld.com/4612/snub_mount_install_005.jpg"></center><p>with my 1B/2B intercooler which is fairly similar to the 3B intercooler you're using.

HTH.

Steve
Michigan

Sleeps 4 at 120

<ul><li><a href="http://www.sjmautotechnik.com/trouble_shooting/turbo.html#intercoo">http://www.sjmautotechnik.com/trouble_shooting/turbo.html#intercoo</a</li></ul>