Forced 4 intercooler install.

[Pat_in_L.A.]

OK guys I finally got to start on the install. First pic is at 3:30 PM with the car in the driveway. Second pic is 20 minutes later at 3:50PM with the car on ramps and the nose removed.

[Pat_in_L.A.]

Here are pics at 4:30PM of the 85.5. Other things were found in the car that need to be repaired so I'll probably have a slower time of it from here on out. I will also be installing a 2R bumper skin when it goes back together.

[Pat_in_L.A.]

So, uh, in the one hour from 3:30 PM to 4:30 PM ... how many beers is that?

Looks like fun!

Four. I woulda got farther if I had six.

[Pat_in_L.A.]

I understand. The day is always another tomorrow. Sorry I wasn't there to help [hold your beer].

That's Ok I'll forgive you. Damn, scope creep is a beeotch!

[Eyelawdoc]

Looks good, Pat! I will be by on Monday to see how far it has progressed.

[Pat_in_L.A.]

Monday may be too late. It may be wadded up by then. (Just Kidding)

[kyle shaw]

I really want that intercooler. How ever it wont do me any good with out a engine in the car.

kyle

[SVOeric]

actually, with the engine out of the car is the perfect time to install it.

[Gyrhead]

I agree with Eric, and if you can take the rad and ac condensor out, it would be even easier. If not, take the facia off. It seems like a PIA, but trust me, it'll make installation and more importantly adjustment for fit so much easer!!! The clearances for the kit are very tight to allow it to co-exist with the AC and fit in the small spaces Ford never intended to have big honking tubes running thru.

[NavySVO]

take the facia off.

Since you have it down to a science, can you beat Pat's elapsed time of 20 minutes (and nearly 2 beers?)?

[Pat_in_L.A.]

Since you have it down to a science, can you beat Pat's elapsed time of 20 minutes (and nearly 2 beers?)?

That 20 minute time was mostly because half the fastners were missing from a previous owner's install. I also found a few missing or loose bellhousing bolts, as well as a ground strap that went to nowhere. Anyways, here are a few more pics.
1) VAM, Air cleaner, Intercooler and Evap cannister removed
2) Upper line, hose, and beverage

[Pat_in_L.A.]

Pic 1) Here's the cold air box. I radiused a few corners. I then used the deburring knife and tongs to roll the corner to relieve the spot where it fit rather tight at the bottom.

Pic 2) Tubes going through core support. Split poly loom added for chafing protection.

[Pat_in_L.A.]

Pic 1) Same tubes, view from other side.

Pic 2) Cold air box in place trial fit.

[Eyelawdoc]

Another Sierra Nevada Pale Ale, I see! Is that your beer or Mike Flemings?

I looks like it is all coming together nicely. The FMIC from Forced4 is easily the nicest part on the car! (shameless plug)

I wonder if some closed cell foam pipe insulation might not work better than the poly loom material to protect the tubing where it passes through the core support?

[Pat_in_L.A.]

1) Box in place, Header panel mounting bolt hilighted.

2) Making a mounting hole with a Whitney punch. Only one slug to clean up rather that using a drill and having shavings everywhere. It's located towards the innermost corner to line up with existing holes in the inner fender panel rather than drill any new holes. After the hole is made, the tongs are used to bend the tab back where it wants to be.