Kevin I think you are doing the honorable thing, I NEVER claimed or hope to achieve better performance than the other cores mentioned, just that I had a hard time justifying the difference in cost. I personally don't blame you for not wanting any part of the ss autochrome intercooler, however, it is refreshing to see you are willing to make a effort to try and help the rest of us. for that I thank you Kevin. I also feel you have debated this topic very well and tried to be as objective as possible.:bigthumb:

Just got mine today. Sonix7, how did you get it to fit sitting straight? I had to slant mine a little to get it to fit with the hood closed.

-Neal

My current duct is designed to be used with the pipes that come with the kit. at least the charge pipe. the one from the IC to the elbow can be custom. my duct is slanted with the bottom fitting between the radiator fans and the front crossmember.

I'm going to try and construct a duct with sheet metal this weekend. My car is out of comission for a while since I broke my air filter trying to reinstall it. I needed to get narrow ones anyway for them to fit right.

Any pics yet?

I think I've already responded to all private messages and the one email about this but I decided not to follow through on the offer above, sorry for the wasted time of those that wanted to buy the duct/tube deal. The two reasons I changed my mind were, A. Might damage the reputation of my IC's since people might assume the core etc. also come from me and B. It isn't fair to those paying for the real kit.

I noticed someone was planning to make a duct for it and sell it already so it shouldn't really hurt anyone.

Kevin T. Wyum

I should have pictures up soon. :)

With a large "XSPOWER" stamped across these intercoolers, how in the hell could someone mistake them for yours? And how is it unfair? If the real kit is so good and worth the cost why should anyone that has the real kit care?

Hmmm, I wonder if Chuck can make a duct for the XSPOWER intercooler? He's the master of replicas. I think I'll PM him.

they might if you sanded the "XSPOWER" off of the top plate like I did. ;)

Well, Sean, you tend to do things a little different than everyone else anyway. :)

:D

I was just saying. It has been mistaken for an M2/asp by an M2/asp owner. My intentions were not to make people think I have an M2/asp. I just dont like the logo right in your face in big ass letters.

I am interested in what you guys come up with? I am finishing up a duct using the inlet of the stock duct and fiberglassed it up. Fits nice, now I need to get it all hooked up. I am having some custom pipes made up so it flows better and meets up with the greddy elbow, so we will see when we are done. I just am so tempted to make a larger duct utilizing more of the space between the bumper support and the radiator, making the duct longer and then I could split it respectively between the intake and intercooler. Bettter air flow it would seem. I don't see how it would bother the radiator especially if you already sealed around the sides, as long as you didn't restrict the back side of the radiator and fans too much. I don't know I will look more at it later. I also agree that the logo in your face is a bit much. Sand and polish would be ok. As far as trying to pass off as other intercoolers, I think its cool that there are choices, free enterprise. I don't see any reason why Kevin or Chuck would want to do this, unless they can't sell anymore of their products. Its not in their best interest, they have a product to promote and sell and should completely believe theirs is the best, otherwise why would anyone buy their stuff? Lets see who has the best design on a DIY duct and go from there.

Be careful how large you make the duct opening. You should keep the opening the same size to prevent air from "overflowing" out of the duct.

So you feel this should be a complete DIY project? There will be no two alike... so performance results will vary.

I think in keeping with the "affordable alternative" theme, whoever makes the best DIY duct should try to make templates like Damian did for his intake.

Its not quite that simple. I guess you could make a frame from the duct and just let everyone fiberglass it themselves.....

You could make it out of sheet metal or aluminum and have the pieces welded together. But if you want to use fiberglass, once the duct is complete, use some Plaster of Paris to make a mold so it can be dulpicated.

used sheet metal the first time...wont use it again. fiberglass is a much better choice, IMO.

What did you not like about it? I was planning on using sheet metal myself.

It was not as solid and sturdy as I would have liked, so I went with fiberglass. The sheet metal will work ok. In my case, I didnt like how hot the metal duct would get from the radiator. I dont know if it had much of an impact, but I figured it could be better.

I just installed the same intercooler but had a huge fitment issue with the pipe from the turbos that was provided. no way no how would it work with my air pump. so after messing with it for about 2 hrs using different couplers and trying to make it work I took off my air pump(was going bad anyway making weird bearing noise) .

The 90 degree bend was still not long enough to fit right?! So I used some intercooler pipe I had from my other setup and mounted it horizontal in the engine bay.

I don't have intake temp #s but after driving 65 miles from work on the freeway and some spirited driving , I was able to grab the outlet pipe going to the throttle body but could not touch the inlet side way to hot. I could not do this with the other intercooler I had (mitsubishi).
Which was a 11x7x3 in core with aluminium end tanks

yeah I know thats not concrete evidence like a temp gun or gauge ,my point is that it didn't heat soak like my other intercooler.

I haven't been running the car in a while but finally got it together and out a couple days ago. Air intake numbers when in the low 40's and I even hit 37 C without a duct. Granted there was not a lot of boosting but I was in stop in go traffic. Not sure what the outside temp was probably upper 60's F. I am still working on smoothing out the plug for my duct to make a mold from. Hopefully in a couple of weeks when I get my mold release and molds finished I will have the first copy to show everyone.

Posting air intake numbers will be pretty much meaningless due to the location of the sensor and the heat soaking issue and also it's relative slow reaction to changes in the charge air temps. Doubt anyone will ever step up and get a true reading from a couple before and after the IC, but like most everyone has stated, it's better than stock and with a duct should be a good alternative.

Tim

I have a couple pics of the duct now for those that are interested. send me a PM with your e-mail if you are interested. Or you can send me an e-mail at twinturbose7en@aol.com.

Would this duct fit on a Greddy SMIC?