DHM Race Crash Bar and Intercooler!

[westcoaST]

I'm going to use a rotary rasp, then a scotchbrite pads to smooth out the rough cut. Both will be on a die grinder. I'll let you know how it turns out, once I get my Intercooler and crash bar.

I got mine at amazon.com $9.69

http://smile.amazon.com/ToolUSA-Rasp-Disc/dp/B00VUGIZF0/ref=sr_1_1?ie=UTF8&qid=1430855481&sr=8-1&keywords=rasp+disc

 

[Hijinx]

http://www.harborfreight.com/8-amp-3-in-x-21-in-professional-belt-sander-69860.html

This is what I was thinking of. I'm pretty sure I've got one.

 

[westcoaST]

The problem with abrasive belts is that they clog up pretty fast and generate lots of heat. That is why I decided to use a cheese grater. The sander would be a good idea once you've removed the majority of the plastic. Rodmoe and others, what did you use?

Just a thought, maybe an air saw would be best to remove the guts, and then sand the rest flush. I'd be too worried about slicing through the edges of the honeycomb.

 

[Hijinx]

Honestly, I was thinking of just drilling large holes instead of sanding it all out.

 

[DHM1]

[MENTION=9]rodmoe[/MENTION]

 

[rodmoe]

[MENTION=9]rodmoe[/MENTION]

YES ?
60 grit to hog out the most then 200 to finsh the edges on a 5 inch orbital sander and a few hrs sanding and then a few picking the black gunk from sanding up lol
I thought of drilling too but i had a hard time finding (aka did not find) a obround drill bit to fit the hex pattern ...

 

[RAAMaudio]

This is what I used and finished it up with a flap disk and then trimmed any flashing off with a razor knife, took about 2-3 hours, I did this nearly a year ago so forget just how long. It can overheat so keep it moving and you will be fine.

http://www.harborfreight.com/4-12-in-Polycarbide-Abrasive-Wheel-60571.html

Should be fine but if you can add a bit more get a Makita, they last for years.

 

[Hijinx]

There really is more than one way to skin a cat.

 

[RAAMaudio]

I have skinned hundreds of them, J/K, but have modded cars a very long time and have around 20 power and air tools just for sanding and tried several before trying what I used as I had it in the abrassives drawer, it worked the best but there might be something else I did not try, I do not have everything

 

[OCDFist]

Crash Bar is ordered. I plan to use the lighter bar & order an Airtec or COBB fmic in June and open up the grill.

 

[JPGC]

Crash Bar is ordered. I plan to use the lighter bar & order an Airtec or COBB fmic in June and open up the grill.

Where do you plan to mount the crash sensors with the new bar? Or is Russ customizing it for you?

 

[JPGC]

i was using some 40 grit sand paper pads on a rotary tool but it was going to be a slow road and i didn't have the time so i put everything back together for now until i decide what else i can use or have more time

Funny day ;-).

 

[OCDFist]

Where do you plan to mount the crash sensors with the new bar? Or is Russ customizing it for you?

Russ's idea was to cut the sensor plate at the bumper bolt flange and bolt it back on with the new crash bar. I'll take pictures when I do the install. Probably won't have patience to wait until I buy a new fmic and I'll be able to see the air flow effects with the factory intercooler.

 

[westcoaST]

When are the next orders shipping? I was told last Tuesday. I was hoping to replace my IC and crash bar this weekend.

 

[RAAMaudio]

If you keep the stock sensor mount at least drill some big holes in it as it is very disruptive to airflow to the condenser and radiator.

 

[OCDFist]

If you keep the stock sensor mount at least drill some big holes in it as it is very disruptive to airflow to the condenser and radiator.

Definitely on the schedule.

 

[RAAMaudio]

I did that at first then when apart for the J-Line IC I made a new bar out of some 1/2 sq tubing for even better flow, I would of used round stock but did not have any on hand, it was also the oil cooler mount.

I highly recommend to use a step bit, easier than other methods, and drill holes in the middle of the grids on the verical plastic part of the core support, or cut it out completely, and then behind where the IC will go drill holes there as well to let more air get out of the back of the IC better.

 

[DHM1]

When are the next orders shipping? I was told last Tuesday. I was hoping to replace my IC and crash bar this weekend.

Im really sorry we hit some major delays on the getting the billet hose ends from our suppier. If they don't ship tomorrow they will be out Saturday.

Russ

 

[westcoaST]

Im really sorry we hit some major delays on the getting the billet hose ends from our suppier. If they don't ship tomorrow they will be out Saturday.

Russ

Thanks Russ. I'll install them the following weekend then.

 

[DHM1]

Thanks Russ. I'll install them the following weekend then.

I'm having some shirts made soon. I'll have to send some for making you guys wait! Sorry again promise it's worth the wait!

Russ