South East Scoobies - DIY STi Intercooler undertray...

After purchasing an STi intercooler my bugeye I started looking around at intercooler undertrays to fit the I/C.

After some hunting around it was apparent that the STi undertray and splitter would only fit within an STi scoop due to its height. As I was unable to afford a scoop, genuine undertray and have it sprayed etc at this moment in time, I decided I would do as the Americans do and fabricate one myself. After all, how hard could it be!!!??

First off, I/C fitted. The cooler came from a Type UK so had plenty of flaking paint, so this was rubbed down and resprayed.

http://i98.photobucket.com/albums/l2...n98/photo4.jpg

I then played around for an hour or so making up a cardboard prototype to fit the shape orientation etc. This involved using my existing etc shape (very roughly) for sizing etc.

http://i98.photobucket.com/albums/l2...n98/photo5.jpg
http://i98.photobucket.com/albums/l2...98/photo23.jpg

This was transferred to some 1.5 ali bought from a local sheet metal firm.

http://i98.photobucket.com/albums/l2...98/photo22.jpg

Let the benning begin...

http://i98.photobucket.com/albums/l2...98/photo20.jpg

I then bolted this up to the car once the bolt holes had been aligned to check for continuity.

http://i98.photobucket.com/albums/l2...98/photo21.jpg
http://i98.photobucket.com/albums/l2...n98/photo6.jpg

Surprised at the fit first time I continued bending and cutting. I got myself a rivett gun to make the finish alot more oem rather than bolting as I had originally intended.

http://i98.photobucket.com/albums/l2...98/photo18.jpg
http://i98.photobucket.com/albums/l2...98/photo19.jpg

Things were now starting to take shape well I thought...

Making the seal was obviously an important factor. Getting it snug was something else. Fortunately my constant measuring had paid off and things fit rather well. I got hold of some vertical rubber boot seal from a local motor factors. However I needed 1.5m and it only came in 4m lengths. So I have some spare!

http://i98.photobucket.com/albums/l2...98/photo17.jpg

It was now time to see how the fit was. I think the pictures show the fit was like. Not bad for first time...

http://i98.photobucket.com/albums/l2...98/photo15.jpg
http://i98.photobucket.com/albums/l2...98/photo14.jpg
http://i98.photobucket.com/albums/l2...n98/photo8.jpg

Old against new...

http://i98.photobucket.com/albums/l2...98/photo13.jpg

As the STi undertray had a built in Splitter/duct, I felt this was now needed. I decided to use a pivot at the back with bolts at the front and elongated holes to allow the splitter to work should I get an STi scoop at a later stage, allowing me to raise the height of the splitter.

http://i98.photobucket.com/albums/l2...98/photo12.jpg

Now fitted with scoop on...

http://i98.photobucket.com/albums/l2...n98/photo9.jpg

Ran this for a couple of days to see how it went and decided to spray it to make it more oem.

http://i98.photobucket.com/albums/l2...98/photo11.jpg

Now finished product...

http://i98.photobucket.com/albums/l2...98/photo10.jpg

Obviously with all the back and forth to fit to the car this took me a good few hours. But I have to admit I'm pretty pleased with it, even if my back did kill for a day or two after from the bending over the table and engine bay.

Total cost for those interested:

1.5mm ali sheet (1250mm x 2500mm) = £6.46
4000mm Rubber boot seal (only 1500mm required) = £15
Spray paint = £6.99

Total = £28.45

Obviously if you want to include the rivett gun etc you can but that was an investment as far as I was concerned...

I just felt that with my lack of engineering background and a little patience, I would share my little effort with some of you...

Comments most welcome of course..

Rich