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Intercooler piping - cutting the holes in the body 

 

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 Post subject: Intercooler piping - cutting the holes in the body
Posted: Sun Feb 24, 2008 12:34 pm 
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Any hints/tips on how to cut the holes in the body to get the intercooler piping? I'm needing two 3" holes were the air box used to be and a 3" hole were the battery tray is.
Is there an easy way to remove the battery tray?
I was thinking of trying to find a 90mm hole saw?

 

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Posted: Sun Feb 24, 2008 2:14 pm 
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I couldnt get hold of a holesaw when i did mine, I just drilled about 20 6mm holes and chisseled it out. Then i cleaned it up with a pencil grinder.

 

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Posted: Sun Feb 24, 2008 2:54 pm 
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90mm hole saw was all i used. It's probably the easiest way to do it.
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Posted: Sun Feb 24, 2008 5:11 pm 
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to remove the battery tray you need to drill out the spot welds.

 

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Posted: Sun Feb 24, 2008 6:08 pm 
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EL XR8 wrote:
90mm hole saw was all i used. It's probably the easiest way to do it.


Cool. I'm probably going to have to drill from underneath on the passenger side as I can't be bothered removing the blower.

 

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Posted: Sun Feb 24, 2008 7:08 pm 
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Be aware that the ABS module is below the airbox, so be careful when drilling through there
Brett

 

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Posted: Sun Feb 24, 2008 8:51 pm 
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When drilling holes in the frame of the car for a front mount intercooler some thing that your car can be defected for ?
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Posted: Sun Feb 24, 2008 10:02 pm 
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TerroristGHIA wrote:
Be aware that the ABS module is below the airbox, so be careful when drilling through there
Brett


Cheers, but it's irrelevant for my pov pack (no ABS).

 

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Posted: Sun Feb 24, 2008 10:03 pm 
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ISQUIK wrote:
to remove the battery tray you need to drill out the spot welds.


Wheres the spot welds?
I can see were it sits on other parts of the body, but I can't see were the particular welds are to be drilled.
Image

 

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Posted: Sun Feb 24, 2008 10:05 pm 
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oxy cutter :D

just joking.

 

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Posted: Sun Feb 24, 2008 10:22 pm 
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twr7cx wrote:
ISQUIK wrote:
to remove the battery tray you need to drill out the spot welds.


Wheres the spot welds?
I can see were it sits on other parts of the body, but I can't see were the particular welds are to be drilled.
Image


for memory there towards the back of the tray so you might have to move that nasty looking wiring. just have a fell around and get happy with drilling the s**t out of your car.

 

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Posted: Mon Feb 25, 2008 7:54 am 
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ISQUIK wrote:
for memory there towards the back of the tray so you might have to move that nasty looking wiring. just have a fell around and get happy with drilling the s**t out of your car.


Stuff it, I can get the little 100mm angle grinder in there prolly be quicker. I'll have a dig this afternoon after uni.

 

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Posted: Mon Feb 25, 2008 10:07 pm 
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Its a pain removing the battery tray, theres about half a dozen spot welds. You think youve got them all and theres another one always hiding somewhere.
Dont forget the spot welds on the side which are attached to the frame rail.

I used a pair of tin snips to cut the holes. Worked ok, was a bit rough but can be cleaned up with a dremel or a file.


To find the spot welds try sand the surface and it should highlight the depressions where the welds are.

 

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Posted: Wed Feb 27, 2008 8:55 pm 
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angle grinders FTW thats all i used ,just cleaned it up with a die grinders and file

 

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Posted: Thu Feb 28, 2008 9:08 pm 
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Can you get defected for cutting holes into the engine bay walls. Are they structural? Surely not. The metal is very thin.
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