| I don't mind paying for some things but $1k for I/C's doesn't make sense to me when I know that's something I can fab with the right core. So I set off in search of a suitable core. I researched here on TT.net and found most of the base info I needed to start my search. What was most important for me was knowing the dimensions I had to work with. So.., I found the sizes of all the most common cores, HKS, Stillen, Greddy, etc. Then I used those measurements and looked for a suitable core and endtanks that could be modified. I used ebay in my search as there are plenty of used I/C's for sale at reasonable prices. Bingo! I found the core from an 87-89 Ford Turbo Coupe (T-Bird). Bar and Plate, made by Blackstone (they made then and now all the I/C's for Saab, Porshe, Audi and a few US domestics) . Then in researching Blackstone I/C's I learned they use a silver solder because it conducts heat better than aluminum solder. The I/C core measured in at 11x6x3=199 cu". This is twice the stock size and the same as an HKS. Also I was able to find all the relavent test specs on the intercooler in it's original configuration. Eff & psi drop at different boost levels and temps. Plus, I know I can improve on that because the original inlet is about 1.75" and that will be changed to meet the ZX inlet at 2". The outlet is 2" so that'll remain but get repositioned. It's not alot of work but it's tedious chasing down this and that and getting everything in place. Then I have to lay the car up for a day and remove my I/C's to fit these then put mine back together while they're getting welded up. Then do it again as I get everything lined up. After I get the first set done I will make 2 more additional sets as I have 6 of these I/C's. I plan on making the ducting for the fascia too. That'll be a fun project in the sheetmetal shop. I have a choice of few materials so I'll decide that later. Once I get the I/C mounted then I can make some templates and then make the ducts. When I finally get it all done I let everyone know how it works. Then I'll complete the other 2 sets and sell em. If they work as well as I think they will then maybe I'll keep going and make 1 set at a time and sell em here. My goal is to keep them inexpensive (affordable). There's some things that cost a little money like silicone connectors and t-clamps but that's out of my control. I figure if I do it in my spare time at work and home they may take a little time to complete but they'll be nice when they're done.
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