Its Official... I Inserted MY 73MM BIG BLACK WANGER

[Lucas_R]

by the sounds of it your installation of the DO888 will cause you or your mechanic troubles when they have to do that.

Nope it was done a month or so after intercooler install. All sweet - thanks for your concern.

the intercooler goes INFRONT of the radiator towards the bumpers.. not In place or partially in place of the radiator ?? it definately should not be pushing the radiator towards the engine..

No $h17 Sherlock. The intercooler has mounting tabs on the bottom which slot into specific spots on the plastic support clip which means the intercooler remains in the same place, then the radiator and a/c condenser attach to either sides of the intercooler. Now - and ill keep this simple for you - because the intercooler is thicker, its means that the radiator is pushed back towards the engine and the a/c condenser is further forward than it was with the original intercooler. Its basic physics!!

Here is one of my pretty pictures for you showing the tabs on the bottom of both the factory intercooler and the do88.

Feel free to refer to my pretty pictures to help you understand what you are doing wrong, as this is why I take said pretty pictures and upload them to this forum - to help others. xoxo

arguing with people who actually know what they are talking about

And who is this other person because it isn't you. You have no idea what you are talking about, and the more you talk the more you prove this.

[amunra]

Nope it was done a month or so after intercooler install. All sweet - thanks for your concern.



No $h17 Sherlock. The intercooler has mounting tabs on the bottom which slot into specific spots on the plastic support clip which means the intercooler remains in the same place, then the radiator and a/c condenser attach to either sides of the intercooler. Now - and ill keep this simple for you - because the intercooler is thicker, its means that the radiator is pushed back towards the engine and the a/c condenser is further forward than it was with the original intercooler. Its basic physics!!

Here is one of my pretty pictures for you showing the tabs on the bottom of both the factory intercooler and the do88.

Feel free to refer to my pretty pictures to help you understand what you are doing wrong, as this is why I take said pretty pictures and upload them to this forum - to help others. xoxo





And who is this other person because it isn't you. You have no idea what you are talking about, and the more you talk the more you prove this.

cool story. id suggest u go dismantle your front end and show your kid how to properly install an intercooler.... your cooling pack is set up the wrong way and you are going to **** something up.. you really are a

the fact you havent trimmed your plastic tray to make the adjustments and have pushed your radiator further towards your engine is major user error .. im sure theres plenty of people laughing at you right now

trimming the plastic tray is a REQUIREMENT to make proper fitment ... i also noticed from your guide that you took the plastic supporting tray off completely which is another user error... i swung mine off together with the condensor like a door ... that way it was in the exact same spot it was before it came off and all adjustments / trimming were made from there for the required fitment.

--- lucas_GTI stupidity aside.


you guys may also see from my before and after photos that the condensor is actually pushed a little more forward than before (you can see the white peel at the top of the condensor) whereas it was sitting further back underneath the tray in the pre installation pics

[Lucas_R]

There is no need to trim any plastic trays if you buy a properly engineered product that fits the car correctly. I'll just leave this here for you so you can see for yourself. https://do88.com.au/wp-content/uploa.../ICM-300-B.pdf

your cooling pack is set up the wrong way and you are going to **** something up..

There is quite literally only 1x way it goes together. It is impossible to have it setup the wrong way. If yours does not look like mine then I can assure you that you have made the mistake, not me.

And the reason why I took additional parts off my car during the install (including the plastic tray) is because I was taking the opportunity to clean everything thoroughly while I could access it to get rid of leaves/rocks/feathers etc. The reason why I swung my plastic tray aside and separated it from the a/c condenser is because of the acc radar in the lower grill. I didnt want to disconnect it and have to get it recalibrated, so the only way around that was to leave it connected which meant swinging the plastic support off to the passenger side.

[amunra]

There is no need to trim any plastic trays if you buy a properly engineered product that fits the car correctly. I'll just leave this here for you so you can see for yourself. https://do88.com.au/wp-content/uploa.../ICM-300-B.pdf



There is quite literally only 1x way it goes together. It is impossible to have it setup the wrong way. If yours does not look like mine then I can assure you that you have made the mistake, not me.

And the reason why I took additional parts off my car during the install (including the plastic tray) is because I was taking the opportunity to clean everything thoroughly while I could access it to get rid of leaves/rocks/feathers etc. The reason why I swung my plastic tray aside and separated it from the a/c condenser is because of the acc radar in the lower grill. I didnt want to disconnect it and have to get it recalibrated, so the only way around that was to leave it connected which meant swinging the plastic support off to the passenger side.

good luck then if your IC is 'designed' to push your radiator closer to the engine.. WT clearly have done it differently (as this is a wagner clone). im still thinking its your user error and were too busy making sure everything was Clean and Pretty for a picture.

I literally had 2 options... Take photos of everything at risk being distracted & ****ing something up.... or Get the job done properly

you clearly had other things going on while installing and skipped a couple of common sense things

[amunra]

Just inspected and took some more photos of the install for you guys to have an even clearer idea what how it came together and what im saying...

to clarify.. my radiator is not pushed towards the engine .. my intercooler is straight and parallel to the radiator with sillicone hoses attached as well and flush as possible (i just did the inlet hose again with an electric wratchet to tighten... that way i could push the hose towards the inlet properly and tighten at the same time.... and the intercooler looks flush and nice while looking from the top.. it cannot possibly get any better than that with the top clips in proper place and everything packed together.

from the front of the car........ the condensor protrudes forward from the plastic package tray by about 4 - 5mm (where as OEM it stops before the end of the plastic tray...) .. so there is approx 15MM extra room inside the tray (which some intercoolers meet perfectly for a perfect oem fitment) and then these larger ones which need trimming and modifiying to have it fit in properly and flush. ... in my case.. +19-20mm extra core means 15mm gets eaten by the tray and 4-5mm pokes ahead.. ..

5mm forward / past the end of the plastic package tray lip (used to stop behind the lip)




unfortunately going from other peoples installs if the intercooler is not sitting flush or pushing the radiator forward.. things going wrong.. but its mainly to do with the core thicknesses.

this is why its important to know what you're actually buying / specs of what you are buying/ why you are buying it / what you are going to get out of it and be prepared to install it properly and do some extra things to make it fit..

there is NO such thing as not modifying the oem trims or tray to install these size intercoolers, end of story.

[Lucas_R]

[EDIT by Manaz: Enough.]

[amunra]

as you guys can see here... the radiator (right) and inlet tank which the sillicone attaches to (left) are right on each other... you may barely have 1mm gap there from close in spection.. and u have about 5- 10mm to fiddle around with the tube and clamp.. so 73MM inlet is about as big as you can fit on the OEM radiator.

Outlet / Sillicone

[amunra]

total depth of the cooling package - Approx 155mm from the top of the cover.

there is still the fans that protrude behind that but i didnt include that just the top plastic tray with contents inside.

should be about OEM + 4 / 5mm of condensor ahead of that slightly.

[amunra]

There is no need to trim any plastic trays if you buy a properly engineered product that fits the car correctly. I'll just leave this here for you so you can see for yourself. https://do88.com.au/wp-content/uploa.../ICM-300-B.pdf



There is quite literally only 1x way it goes together. It is impossible to have it setup the wrong way. If yours does not look like mine then I can assure you that you have made the mistake, not me.

And the reason why I took additional parts off my car during the install (including the plastic tray) is because I was taking the opportunity to clean everything thoroughly while I could access it to get rid of leaves/rocks/feathers etc. The reason why I swung my plastic tray aside and separated it from the a/c condenser is because of the acc radar in the lower grill. I didnt want to disconnect it and have to get it recalibrated, so the only way around that was to leave it connected which meant swinging the plastic support off to the passenger side.

from ur DO88 install link.. STEP 28 (LAST STEP)

- Re-install all other parts in reverse order. Note! If thesupport center bracket behind the grille emblem isclose to the AC-condenser make sure the screw doesnot interfere with the AC-condenser when tighteningit. If the screw is to long, please cut it shorter.-

___________________________________________

this would be because your condensor is pushed further forward same case as mine.

no where in that instruction does it tell you push the radiator forward or anything like that.. it does not even tell you how to properly fit it in.. they just assume it will go in nicely with the OEM radiator tabs.

I guarantee you didnt clip it in the bottom properly and because you didnt make any trimming... your IC brackets are getting blocked by the Radiator Tabs.. .. now ur intercooler is angled and pushing the radiator forward to fit it all in and get the hoses clamped up.

[Lucas_R]

Its Official... I Inserted MY 73MM BIG BLACK WANGER

- Re-install all other parts in reverse order. Note! If thesupport center bracket behind the grille emblem isclose to the AC-condenser make sure the screw doesnot interfere with the AC-condenser when tighteningit. If the screw is to long, please cut it shorter.-


this would be because your condensor is pushed further forward same case as mine.

Have I not already said this about 3 times already?

I guarantee you didnt clip it in the bottom properly and because you didnt make any trimming... your IC brackets are getting blocked by the Radiator Tabs.. .. now ur intercooler is angled and pushing the radiator forward to fit it all in and get the hoses clamped up.

Wow holy moly you are right!!!! Look how badly aligned my radiator is!! That got to be at least a 0.1% angle its on. Do you honestly think im that much of a noob that I wouldn't realise if my radiator was installed correctly? Rest assured its correctly mounted into the slots at the base of the intercooler and then clicked in at the top. Its nicely secured and isn't going anywhere. Nothing is rubbing anywhere - I was actually under the car on Sunday installing a new front lip and gave everything a good looking over.

[Lucas_R]

While im not going to try and deny the zoom level is different on these two pics, even Stevie Wonder could see that in the 2nd photo the radiator is pushed several centimetres back towards the engine when compared to the 1st photo.

As I mentioned earlier, the intercooler is the only part in that radiator/intercooler/ac conderser package that is actually mounted to the car, the radiator and ac condenser simply bolt onto the intercooler. So if the intercooler is thicker, both the radiator and ac condenser are going to be pushed away, with the radiator closer to the engine and the ac condenser closer to the front of the car.

I can see your car is still in pieces, so once you get it back together hopefully you will see the light.

[amunra]

if the radiator stays in the same place and you bolt the intercooler to the front.. technically it should be taking up more room at the front / condensor side without taking up the radiators old space.. therefore not pushing anything extra into the engine bay.. it should be where it was.

why are you taking up the radiators space?.. its meant to be kept in the same space with the new ic bolted onto the front not in place.

[EDIT by Manaz: I had to cut some of this out.]

[amunra]

heres a photo of the gap between the recently pushed forward condensor and the 'extended' screw that do888 warn of touching ur condensor.. as you can see there is daylight between the 2 and the camera actualyl couldnt capture the screw.. maybe 1 1/2 - 2 inches gap.

1 small screw (need to find something very small) to secure the condensor as it 'may' move when u try to move it by force.. better to be sure... the other side is very secure and does not move so worked out.


i also found after installing my sillicone hoses that the area were the radiator tab formerly was and the ic were slightly misalligned by approx .5 - 1cm... i slid under the car and literally pushed the radiator / fans towards the bumper with 2 fingers and heard it click back into place ..... had a look from the top and it was perfect allignment.. re-did the sillicone again with the electric ratchet and then 10inch hand too (another 10 - 15 turn) to really secure it and it was perfect..

menacing big black wanger in the background.

[amunra]

update - (relevant to anyone installing any IC really and / or re-assembling the front end)

when trying to put my headlights back in i noticed the screw hole thread for the headlight bolt which is in the cooling pack plastic tray was actually shifted forward by about 5mm and didnt allow for the screw to enter.. more on the left side and about 2mm on the right side.


my error was the screw hole thread next to the crash bar bolts cannot be pushed towards the engine ( i didnt notice when i was reassmbling the crashbar and fastening the plastic tray..) to fix this i needed to undo the screw (t30) and the tray needs to be pulled back towards the bumper a little bit (you will see the screw hole more in the middle or closer to the bumper rather than at the engine side... so the hole lines up with where the headlight screw hole goes when you put the headlight back in ... this will allow reassembly and to be all flush and fasten all the bolts.

[amunra]

hello all just a quick update as i know you guys love my posts especailly me talking about my BIG BLACK WANGER.

I used some black RTV sillicone to secure the condensor tabs onto the intercooler instead of a self tapping screw.

All pretty solid and doesnt move at all.

Job done.

Thanks for reading