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Old 05-08-2010, 09:49 PM   #1
paintbing
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Default DIY Hooscoop Splitter for big TMIC

I recently purchased the JDM STI hoodscoop for my bugeye and also picked up a new TurboXS TMIC. After installing the hoodscoop, I noticed the stock splitter was not efficient in filling up the scoop. It left a good 1/2 inch of space between the scoop and splitter.

I then installed the TXS TMIC and saw how much more of a splitter that was needed. I searched everywhere and couldn't find a decent DIY on how to modify the stock splitter to be efficienct enough for the TMIC. Since I wanted this to be sort of a budget build I wanted to go as cheap as possible. The theory behind this is two-fold. First is to raise the heighth of the splitter to maximize the use of the scoop. Second is to widen the opening so more air can be directed over the TMIC.

Tools needed:
Drill with 3/16" bit and 1/4" bit
Sheet Metal Snips
12"x12" galvanized sheet aluminum (0.028 thick)
3/16" x 5mm pop rivets (15 of them)
Can of Black Spraypaint
Sharpies
Piece of paper/Cardboard
Patience
Optional: Dremel with cutting disc

After I started into this project I realized I should document my progress. First off, I took a paper and/or cardboard to create a template. I laid the paper on the intercooler and then penciled the outline of the big TMIC. I then closed to the hood and then reached inside the hoodscoop to mark where the stock splitter seal/weather stripping hit the intercooler. With this, I can directly see where the stock splittler can be opened up so that we can direct the airflow across the new TMIC.

I started off by removing the rubber seal being carefull not to damage the little plastic clips. I resuse these later. I then cut out my template so that all I had left was the portion of the TMIC that needed to receive air. It looked like a giant "C" or "U". I laid this on the bottom of the stock splittler and marked where the new opening had to be.

Next I used the 1/4 drill to drill out the 5 tack welds that held the edge bracket. I removed the Drivers side all the way and left half on the passenger side. I then used this piece as a template for my new angle brackets. (Picture Below)

I then used a dremel to expand the opening on both sides.

*Make note here that because the TMIC is long, the rear edge of the TMIC actually sits at the back edge of the splitter, so I was unable to cut all the back. I stopped about 1.5 inches from the back.
I had access to a friends splitter to "practice" this on.

Passenger side I left part of the bracket to use to attach the new expanded splitter.

Note the space I left from the rear edge. Note I drilled a "stop" at the end so that it vibrations from the car wouldn't let the new cut to keep running.

Comparison of the two splitters. Note the top one has been re-bent closer to the backside of the splitter. (this was a pain in the butt!) I first flattened the exisitng bend, then used a makeshift break (kitchen counter edge) to rebend at the end of my new cuts.

Template - I cut it bigger than I knew I would need to give myself room for error and trimming. Since the angle of the splitter will be a little higher than stock (to fill the hoodscoop) you will need to adjust the angle a bit. Trial and error.


My new template. I did MANY dry-fitting before I revited this in place. I used the 3/16 bit to drill my new holes. (Note the 3/16 bit is the SAME bit you'll use for relocating the plastic pop-rivits for the rubber sealer.)


Rivited in place!

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Last edited by paintbing; 05-09-2010 at 06:15 PM.
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Old 05-08-2010, 09:50 PM   #2
paintbing
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I then painted the new pieces. I just painted the exposed parts. Since this is galvanized aluminum, it should last as long as I need it to last. Below are some different shots of the semi-finished product.






In this picture you can see that I've reused the oem rubber molding.



I ended up starting at the front of the splitter and then worked my way to the new edge. I had to cut the lip so that it rounded the corner without deforming too much. Again, I used the 3/16 drill bit to drill new holes for the plastic taps. It's a perfect fit! Once I reached the backside of the splitter, I cut the remaing rubber off. I then started back in the middle again with the other end of the leftover rubber. Notice I am done with the exception of the rear piece. This is where the back plate of the splitter reaches the back of the TMIC.

Since I had two stock splitters to use, I used the rubber from the spare one. However before I used the spare rubber, I tried to find a good weather/garage door sealer to use, but didn't find anything I liked. This back rubber piece really only needed to be ~1/2" thick. I attached the back piece with the stock plastic clips.



I test-fitted the piece and noticed that on one side, the edge of the TMIC caught the rubber just barely and folded over one row of fins. To remedy this, I reached inside the scoop and pushed the rubber off the TMIC so it hung over the side. I then took a sharpy (again with hood closed) and drew where I had to trim the rubber. After trimming, the rubber gently sits on the edge of the TMIC creating a perfect seal.



This was my only screwup... Since the one side was slightly off, the other side was slightly off too, so as you can see, I have about 1/4" of a gap that I haven't been able to deal with yet... I think I'll just leave it to help push the turbo heat away though.


Last edited by paintbing; 05-09-2010 at 04:00 PM.
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Old 05-08-2010, 09:50 PM   #3
paintbing
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Reserved for Expansion
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Old 05-08-2010, 10:10 PM   #4
hoffmanEstates
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awesome now you should try to add extra fins as in the gt spec version. it will divert air better as it is lazy and takes the easy way out of working
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Old 05-08-2010, 11:41 PM   #5
paintbing
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I already thought of that, but ran out of time today. More than likely I will add the extra diffuser/fin in coming weeks.

More details to follow in posts above. Gotta step away from the computer though.
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Old 05-09-2010, 01:48 AM   #6
evan_impreza
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nice. a good ole' diy is always fun.
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Old 05-09-2010, 12:39 PM   #7
offcambersm
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nice! i always use aluminum or plastic when i can get away with it.
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Old 05-09-2010, 12:53 PM   #8
nicholam
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That's exactly what I did! Good job!
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Old 05-09-2010, 01:13 PM   #9
GraphicWRX
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Nice work. I am thinking of doing the same. I may go with the FMIC though...hmmm
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Old 05-09-2010, 02:36 PM   #10
SupaHottSauce
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I did this same thing about a year ago, except I used some thin steel to rework the entire scoop. I was able to weld it to the base, and I added a second splitter in the center of the scoop to direct more to the front.

It came out really good, however it is a little bit heavier than I would like but oh well. I really wish I had pictures, but I dont.
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Old 05-09-2010, 04:01 PM   #11
paintbing
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Hopefully this will be of help and give people another option wrather than trying to source an STI splitter and/or aftermarket splitter.

^ and yes, I will be adding a second dividing splittler when I get more time.

Cheers!
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Old 05-09-2010, 04:09 PM   #12
573
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Here's my first attempt at a DIY splitter.


It has served me well for a while, but it's looking pretty jankity now. I have a process west intercooler now so I'll be making a new one in the next few weeks to nicely mate up with that.
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Old 05-09-2010, 05:49 PM   #13
OrbitalEllipses
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Quote:
Originally Posted by 573 View Post
I have a process west intercooler now so I'll be making a new one in the next few weeks to nicely mate up with that.
Process West makes their own splitters. RallySportDirect.com is their sole US distributor. As well, their forum name is OZwrx. Chat it up with them to see what's up.
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Old 05-09-2010, 05:52 PM   #14
hoffmanEstates
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now this is a shot in the wind,
what about splitter's on a fmic? there is nothing there just the core and open space. i always thaught about that just i dont have a test unit to try it on.
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Old 05-09-2010, 06:17 PM   #15
paintbing
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I suppose you could create something to help "catch" the air, on the FMIC, so that some direct airflow does't roll off the sides,but Not sure how you could accomplish this AND make it look good... All I can picture is a concept that takes it's design from a dog shade (ie the lamp shade thingy dogs wear sometimes).
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Old 05-09-2010, 08:13 PM   #16
573
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Quote:
Originally Posted by OrbitalEllipses View Post
Process West makes their own splitters. RallySportDirect.com is their sole US distributor. As well, their forum name is OZwrx. Chat it up with them to see what's up.
I'm aware. Spending $200 on theirs seems pretty nonsensical when I can make one of equal quality in a few hours for around $20.
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Old 08-15-2010, 01:33 PM   #17
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old bump lol
omg make me one for my sti tmic
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Old 09-16-2010, 10:43 AM   #18
krauser2
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this is extra impressive guys....going this route for sure with my wrx splitter
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Old 10-11-2010, 07:50 AM   #19
2:43AM
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Great writeup. This is exactly what I was looking for. The OP was right. There was never a decent writeup before this. Everyone always says, "modify your stocker," but no backing up that statement. Great DIY. Thanks.

Question, however. Would the 04-05 hood be any different than the 02-03's for underhood fitment? After all, the 04-05 STi air splitter, I think is bigger, but more so in height to fill in that giant scoop!
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Old 10-11-2010, 07:58 AM   #20
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Most aftermarket splitters direct and distribute air equally over the TMIC. The one the OP made will just cool the top part of the TMIC.
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Old 10-11-2010, 08:25 AM   #21
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Quote:
Originally Posted by quazimoto View Post
Most aftermarket splitters direct and distribute air equally over the TMIC. The one the OP made will just cool the top part of the TMIC.
The OPs design, once fixed, will help force the air through the TMIC which will improve cooling. Yes some of them have a fancy divider but Im not totally convinced those work all that well. The name of the game is to get the air through the IC, not just on it.
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Old 10-11-2010, 08:25 AM   #22
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Quote:
Originally Posted by quazimoto View Post
Most aftermarket splitters direct and distribute air equally over the TMIC. The one the OP made will just cool the top part of the TMIC.
Not sure what you mean. By reviewing the DIY again, it looks like he essentially created a "higher" splitter, almost (if not) the same as the 04-05 splitter. However, by trimming the one side, he extended the air flow to the region not covered by any stock air splitter. This writeup SHOULD work to improve airflow over 98% of the surface area of the TurboXS TMIC.
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Old 10-11-2010, 08:34 AM   #23
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Old 10-11-2010, 08:38 AM   #24
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That does nothing for me. Sorry. Haha, I gotta give you a hard time because a) you're on the "other" website and b) you're basically the only guy that responds to my posts!

But yes, the above air splitter has additional fins which YES directs more air evenly towards the front. I can see that. Very good design, but costs big bucks. Keep in mind that the 04-05 splitter does have 2 fins rather than just a big, open area like the OP's splitter. It will help.
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Old 10-11-2010, 09:31 AM   #25
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Quote:
Originally Posted by quazimoto View Post

Those fins mean nothing if there is not a good seal to direct air through the TMIC.
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