Welcome to the North American Subaru Impreza Owners Club Friday August 26, 2016
Home Forums WikiNASIOC Products Store Modifications Upgrade Garage
NASIOC
Go Back   NASIOC > NASIOC General > Interior & Exterior Modification

Welcome to NASIOC - The world's largest online community for Subaru enthusiasts!
Welcome to the NASIOC.com Subaru forum.

You are currently viewing our forum as a guest, which gives you limited access to view most discussions and access our other features. By joining our community, free of charge, you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is free, fast and simple, so please join our community today!

If you have any problems with the registration process or your account login, please contact us.
* Registered users of the site do not see these ads. 
Reply
 
Thread Tools Display Modes
Old 09-15-2008, 04:57 AM   #1
efaroh
Scooby Specialist
 
Member#: 166947
Join Date: Dec 2007
Chapter/Region: SCIC
Location: OC
Vehicle:
2006 WRX Sedan
Crystal Gray Metallic

Default DIY: Intercooler Screen Mod - The right way!

The tmic is horridly vulnerable to bent fins due to rocks, bugs, debris, u-name-it entering the hood scoop. Solution is to block the debris with a screen. I've seen this done 2 ways.

1. lay a screen over the intercooler. Not very effective imo because if the screen gets bent, the intercooler fins, in turn, will get bent. also the rubber apron on the splitter makes an air tight seal with the intercooler. by laying this screen on top of the intercooler, this seal is not tight and the resulting air leakage reduces the efficiency of the tmic.

2. put a screen in front of the hood scoop. Not very attractive imo. also because this disrupts the air flow before hitting the splitter, it affects the amount of air being directed to the intercooler.

Because of the shortcoming of the 2 methods, I decided to make one that performs while minimizing the drawbacks. I used aluminum mesh vent screen available at lowe's. This was ideal because the spacing of the mesh would keep out anything bigger than a grain of rice. it hardly put any restrictions on air flow. I tested this out by blowing through it and felt the same force as without the mesh. also aluminum is the way to go because it won't rust and will bend and form to shape while providing excellent strength.

Placement of the mesh is the biggest reason why it's the right way IMHO. I placed it between the splitter and the rubber apron. that way if the screen gets bent, it wont transfer the damage to the intercooler. it doesnt affect the rubber apron and is still allowed to make a tight seal. Its placed fairly deep in the scoop and is not noticeable unless you stick your head right in front of the hood scoop.

teaser


I would have painted it black if i had any paint at the time i did this. either way its hardly noticeable unless u bend over and take a good look inside the scoop.

A week later, I found irrefutable evidence that my screen mod works!



That bug would have surely bent a couple of my fins. I was so relieved to have done this mod because i had just spent over an hour straightening out all the bent fins with a tweezer!

You can find my walkthrough for it here:
http://www.flex-innovations.com/ic_screen.htm
* Registered users of the site do not see these ads.
efaroh is offline   Reply With Quote
Sponsored Links
* Registered users of the site do not see these ads.
Old 09-15-2008, 09:04 AM   #2
caracer22
Scooby Specialist
 
Member#: 171076
Join Date: Feb 2008
Chapter/Region: SCIC
Location: Lancaster, CA.
Vehicle:
2011 Wrx DGM
STG 2

Default

nice!!!
caracer22 is offline   Reply With Quote
Old 09-15-2008, 11:25 AM   #3
baumer11
Scooby Newbie
 
Member#: 181021
Join Date: May 2008
Location: Calgary, AB, Canada
Vehicle:
2004 WRX Wagon
Java Black Pearl

Default Great DIY

I have to do this as I've noticed a bunch of small rocks and bugs sitting on top of my IC. Did you take your IC out to straighten the fins or do it while it was installed?
baumer11 is offline   Reply With Quote
Old 09-15-2008, 12:45 PM   #4
Tahoe SC
Scooby Specialist
 
Member#: 131996
Join Date: Nov 2006
Chapter/Region: SCIC
Location: Lago forestal
Vehicle:
2006 CGM WRX Wagon
Yimi Tuned 296AWP/322TQ

Default

i need to do this as well! the passenger side of my intercooler looks like it got hit by a fist!

you can straighten out the fins with it on or off the car. probably better off the car as you save your back and can watch tv while doing it!

also be good time to spray other stuff out.
Tahoe SC is offline   Reply With Quote
Old 09-15-2008, 04:11 PM   #5
efaroh
Scooby Specialist
 
Member#: 166947
Join Date: Dec 2007
Chapter/Region: SCIC
Location: OC
Vehicle:
2006 WRX Sedan
Crystal Gray Metallic

Default

Although is it very well possible to straighten out the fins while the intercooler in on the car, your back will be sore in minutes and you wont have total control of the tweezer. I did this mod while installing a silicone y-pipe so the intercooler was already conveniently out of the engine bay. It takes some time and patience so make sure to leave yourself plenty of time.

now that i think of it, a compressed air can would have been handy at the time.. it would've definitely help clean up the stuff thats actually deep inside the intercooler.

other things you could do while the intercooler is out is add a turbo heat shield, upgrade the transmission ground line, etc.
efaroh is offline   Reply With Quote
Old 09-15-2008, 07:48 PM   #6
bugeye1257
Scooby Specialist
 
Member#: 188598
Join Date: Sep 2008
Chapter/Region: Tri-State
Location: Pa
Default

i will prob do this sometime this week
bugeye1257 is offline   Reply With Quote
Old 09-15-2008, 11:53 PM   #7
02boxer
Scooby Specialist
 
Member#: 139853
Join Date: Feb 2007
Chapter/Region: MWSOC
Location: the arsenal of democracy Mich.
Vehicle:
2002 wrx....its tsxy
silver

Default

on the list once I get a new IC
02boxer is offline   Reply With Quote
Old 09-16-2008, 02:08 AM   #8
efaroh
Scooby Specialist
 
Member#: 166947
Join Date: Dec 2007
Chapter/Region: SCIC
Location: OC
Vehicle:
2006 WRX Sedan
Crystal Gray Metallic

Default

the screen mod doesn't involve anything to do with the intercooler. it is modding the splitter, so it can be done seperately from any intercooler mods.

it takes 7 screws and a plastic tab to remove it. takes about 5 min to take apart the rubber apron.

the screen is easy to handle. i made a prototype first just to get a feel for how to handle the material. it kinda reminds me of aluminum foil except a lot more sturdy. after that just cut the screen with scissors and fold the edges to prevent fraying. Trimming is necessary in some areas for it to fit. it takes some knack to get the pop rivets to fit back in because the mesh adds thickness to the depth that the rivets need to hold down. overall it took me 30-45 min. to do this mod from taking off the splitter to putting it back on.
efaroh is offline   Reply With Quote
Old 09-16-2008, 06:51 AM   #9
BeBop86
Scooby Guru
 
Member#: 147776
Join Date: May 2007
Chapter/Region: NWIC
Location: Bellingham, WA
Vehicle:
'02 Impreza WRX
'85 Toyota Corolla

Default

How do you clean it when it gets full of bugs?

Nice write up though!
BeBop86 is offline   Reply With Quote
Old 09-16-2008, 11:06 AM   #10
efaroh
Scooby Specialist
 
Member#: 166947
Join Date: Dec 2007
Chapter/Region: SCIC
Location: OC
Vehicle:
2006 WRX Sedan
Crystal Gray Metallic

Default

Quote:
Originally Posted by BeBop86 View Post
How do you clean it when it gets full of bugs?

Nice write up though!
THANKS! to clean it, the splitter has to be removed, turned upside-down and shaken up a bit. any remaining debris can be removed with compressed air either from a can or a compressor. for anything after that, tweezers should do the trick
efaroh is offline   Reply With Quote
Old 09-16-2008, 04:23 PM   #11
chris-man
Scooby Specialist
 
Member#: 90572
Join Date: Jul 2005
Location: Fullerton California
Vehicle:
2013 WRX STI
07 ninja ZX6R

Default

good mod but i doubt that the bug pictured would of bent a fin
chris-man is offline   Reply With Quote
Old 09-16-2008, 05:27 PM   #12
Tahoe SC
Scooby Specialist
 
Member#: 131996
Join Date: Nov 2006
Chapter/Region: SCIC
Location: Lago forestal
Vehicle:
2006 CGM WRX Wagon
Yimi Tuned 296AWP/322TQ

Default

Quote:
Originally Posted by efaroh View Post
THANKS! to clean it, the splitter has to be removed, turned upside-down and shaken up a bit. any remaining debris can be removed with compressed air either from a can or a compressor. for anything after that, tweezers should do the trick
a dyson vacuum will do the trick! or just blow out the mofo.

yea that's a puny bug...but i see some others that will jack up an intercooler...
Tahoe SC is offline   Reply With Quote
Old 09-16-2008, 05:35 PM   #13
efaroh
Scooby Specialist
 
Member#: 166947
Join Date: Dec 2007
Chapter/Region: SCIC
Location: OC
Vehicle:
2006 WRX Sedan
Crystal Gray Metallic

Default

Quote:
Originally Posted by chris-man View Post
good mod but i doubt that the bug pictured would of bent a fin
haha. the fins are very very delicate. it'll bend even if you just touch it. if the bug entered the scoop while even going 55mph... well u get the point... it wouldve been disaster!
efaroh is offline   Reply With Quote
Old 09-16-2008, 08:53 PM   #14
BeBop86
Scooby Guru
 
Member#: 147776
Join Date: May 2007
Chapter/Region: NWIC
Location: Bellingham, WA
Vehicle:
'02 Impreza WRX
'85 Toyota Corolla

Default

So does bending the fins back fix the intercooler 100%?
BeBop86 is offline   Reply With Quote
Old 09-17-2008, 11:26 AM   #15
efaroh
Scooby Specialist
 
Member#: 166947
Join Date: Dec 2007
Chapter/Region: SCIC
Location: OC
Vehicle:
2006 WRX Sedan
Crystal Gray Metallic

Default

not so sure about 100% but I bet it restores the efficiency somewhat by allowing air to go through where it couldn't before. plus it looks nicer without all the bent fins
efaroh is offline   Reply With Quote
Old 09-18-2008, 01:50 PM   #16
efaroh
Scooby Specialist
 
Member#: 166947
Join Date: Dec 2007
Chapter/Region: SCIC
Location: OC
Vehicle:
2006 WRX Sedan
Crystal Gray Metallic

Default

there's been some debate about screens impeding air flow to the intercooler.

http://www.clubwrx.net/forums/exteri...right-way.html

can any suby guru answer which is more detrimental to ic efficiency: ic w/ bent fins or ic w/ screen?
efaroh is offline   Reply With Quote
Old 09-18-2008, 02:37 PM   #17
Cyclonus
Scooby Specialist
 
Member#: 161701
Join Date: Oct 2007
Chapter/Region: VIC
Vehicle:
40 iTS U-R-A-BUS
BRW

Default

[quote=efaroh;23750502]there's been some debate about screens impeding air flow to the intercooler.
quote]

I'm not a guru, but I don't think "impeding" would not be the best word choice. Technically it still has small holes for air to go through. Think about it this way, the mesh on some house windows help impede big bugs from entering the house, but it still allows air flow too.

It probably just slows down the cooling rate of the intercooler.
Cyclonus is online now   Reply With Quote
Old 09-18-2008, 05:27 PM   #18
efaroh
Scooby Specialist
 
Member#: 166947
Join Date: Dec 2007
Chapter/Region: SCIC
Location: OC
Vehicle:
2006 WRX Sedan
Crystal Gray Metallic

Default

wrxdrvr from ClubWRX forums inserted temperature probes in the intercooler to test IC temps of the two lesser methods I have originally posted in this thread. He used 1/4" wire screen which is thicker than the vent screen mesh that i used.



Test #1 - Mesh on the IC

"Airflow test...A minimum 1*F to 2*F warmer than without wire mesh. No noticeable difference in time to cool down "

Test #2 - Mesh in front of hood scoop.

"Airflow test...A minimum of 5*F to 6*F warmer IC with wire mesh than without. Also takes about 2X + longer to cool IC down to as cool as it\'s going to get then without the wire screen."

my question is: is a 2*F warmer IC worth preventing bent fins??
efaroh is offline   Reply With Quote
Old 09-18-2008, 06:43 PM   #19
BeBop86
Scooby Guru
 
Member#: 147776
Join Date: May 2007
Chapter/Region: NWIC
Location: Bellingham, WA
Vehicle:
'02 Impreza WRX
'85 Toyota Corolla

Default

whats with the foil?

which impeded flow more, on the scoop or on the intercooler?

what about slightly above the intercooler? shouldn't that impede flow less?
BeBop86 is offline   Reply With Quote
Old 09-18-2008, 08:01 PM   #20
efaroh
Scooby Specialist
 
Member#: 166947
Join Date: Dec 2007
Chapter/Region: SCIC
Location: OC
Vehicle:
2006 WRX Sedan
Crystal Gray Metallic

Default

Quote:
Originally Posted by BeBop86 View Post
whats with the foil?

which impeded flow more, on the scoop or on the intercooler?

what about slightly above the intercooler? shouldn't that impede flow less?
the foil is actually heat wrap that prevents heat soak to the IC.

the screen on the scoop impeded flow more than on the intercooler.

I would suspect a screen slightly above the intercooler to be somewhere in between, with similar results to on the intercooler.
efaroh is offline   Reply With Quote
Old 09-18-2008, 09:47 PM   #21
BeBop86
Scooby Guru
 
Member#: 147776
Join Date: May 2007
Chapter/Region: NWIC
Location: Bellingham, WA
Vehicle:
'02 Impreza WRX
'85 Toyota Corolla

Default

So you just taped foil onto the edges of the intercooler, how does that help?
BeBop86 is offline   Reply With Quote
Old 09-18-2008, 10:02 PM   #22
STINOMORMONEY
*** Banned ***
 
Member#: 183029
Join Date: Jun 2008
Chapter/Region: South East
Location: FLORIDA
Vehicle:
2007 STI- 402whp/436
OBP- uncorr./SAE-Mustang

Default

you guys really feel you get that many dings on your top mounts to waste time, money, and a minute amount of flow putting a screen on- fmic- yes but i never experienced problems with the tmic

just curious
STINOMORMONEY is offline   Reply With Quote
Old 09-19-2008, 11:03 AM   #23
efaroh
Scooby Specialist
 
Member#: 166947
Join Date: Dec 2007
Chapter/Region: SCIC
Location: OC
Vehicle:
2006 WRX Sedan
Crystal Gray Metallic

Default

Quote:
Originally Posted by BeBop86 View Post
So you just taped foil onto the edges of the intercooler, how does that help?
thats not foil. its more like heat reflective tape... similar in concept to this: http://www.flex-innovations.com/intake_wrap.htm

Quote:
Originally Posted by STINOMORMONEY View Post
you guys really feel you get that many dings on your top mounts to waste time, money, and a minute amount of flow putting a screen on- fmic- yes but i never experienced problems with the tmic

just curious
if you visit my walkthrough, i posted a comparison between my ic with bent fins and after i straightend all of them out with a tweezer. its a pain is the arse to straighten all of them out!
efaroh is offline   Reply With Quote
Old 09-19-2008, 12:26 PM   #24
Tahoe SC
Scooby Specialist
 
Member#: 131996
Join Date: Nov 2006
Chapter/Region: SCIC
Location: Lago forestal
Vehicle:
2006 CGM WRX Wagon
Yimi Tuned 296AWP/322TQ

Default

i would think that efaroh's placement should yield the same temps as placing it as closer to the intercooler as in the test. once air makes it into the scoop it only has 1 way to go and that's down towards the intercooler. 1-2 degree f isn't much at all. the faster the speed, the more it would impede flow. around town shouldn't see much of a difference. i can see why putting it right at the scoop opening impede much more flow though.

i think it's a great mod for a piece of mind and to save some bent fins.
Tahoe SC is offline   Reply With Quote
Old 09-19-2008, 01:23 PM   #25
efaroh
Scooby Specialist
 
Member#: 166947
Join Date: Dec 2007
Chapter/Region: SCIC
Location: OC
Vehicle:
2006 WRX Sedan
Crystal Gray Metallic

Default

for comparison purposes, here are pics of ic with bent fins vs ic with fins straightened out.

bent finz


after tweezers


after all that painstaking work, i would want to preserve those delicate lil finz
efaroh is offline   Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
Grounding mod FAQ the right way thread pics too! Davenow Electrical & Lighting 727 08-03-2015 10:10 AM
Fog Lights on with Highs Mod for 2000 RS, the right way IowaRS Electrical & Lighting 12 12-03-2010 01:23 AM
Finally did the Intercooler screen mod GooWakJai Member's Car Gallery 23 03-30-2006 08:24 AM
Head light mods, the right way. Iggy76 Electrical & Lighting 12 01-11-2006 07:16 PM
just got the car, modding the right way? sheizen Factory 2.5L Turbo Powertrain (EJ Series Factory 2.5L Turbo) 3 06-16-2005 12:05 AM

All times are GMT -4. The time now is 04:40 AM.


Powered by vBulletin® Version 3.7.0
Copyright ©2000 - 2016, Jelsoft Enterprises Ltd.
Powered by Searchlight © 2016 Axivo Inc.
Copyright ©1999 - 2016, North American Subaru Impreza Owners Club, Inc.