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Intercooler Removal

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Old 02-08-2023, 10:50 AM
  #16  
Metal Guru
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Originally Posted by das76
Should I strip all the paint off to bare AL, then primer + paint?
Is there anything in particular about these hoses , or just preventative on 33 year old hoses?
I would try to get off as much of the old paint that I could so there wouldn't be any adhesion issues.
My hoses were behaving like overcooked pasta so I figured I'd just replace them.
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Scott Dunavant (02-09-2023)
Old 02-08-2023, 12:55 PM
  #17  
das76
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Originally Posted by Metal Guru
I would try to get off as much of the old paint that I could so there wouldn't be any adhesion issues.
My hoses were behaving like overcooked pasta so I figured I'd just replace them.
Thanks. (hopefully) last question: should i media blast the IC housing (covering up the hose/pipe holes) or use paint stripper?
Old 02-09-2023, 12:09 AM
  #18  
Scott Dunavant
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I would like to say mine held up perfect for 22 years sitting outside. But the intercooler made it. I use SEM's trim black. Wipe down with lacquer, Scuff with Grey scotchbrite pad, Apply thin coats of SEM's trim black. Touch up when you need to.

Old 02-09-2023, 01:16 AM
  #19  
das76
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thanks @Scott Dunavant . I'm assuming you mean lacquer thinner? is it necessary to remove all the old paint? I'm guessing not - I can just paint on top of the current layers (minus whatever comes off from the thinner and the scotch brite).
Old 02-10-2023, 03:15 PM
  #20  
997 tt/rs
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I did this alone today 🙃 15 minutes..
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Old 07-01-2023, 02:17 AM
  #21  
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Anyone ever remove the shroud?

I was thinking of painting it red like the turbo s.
Old 07-01-2023, 07:01 AM
  #22  
fritz k.
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Originally Posted by LOMartin
Anyone ever remove the shroud?

I was thinking of painting it red like the turbo s.
Yes, I already had the fan housing out with the engine in the installation situation. It's a bit fiddly because it sits low and just behind the closing panel but it is possible. The alternator is screwed onto the housing from behind and the cables have to be disconnected. If you have DIY experience on the car I would do it, otherwise leave it alone.

Fritz
Old 07-01-2023, 08:17 AM
  #23  
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I would stay away from media blasting an intercooler, last thing you want is small particles going into the intercooler then into the engine and you have scratched bores
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Old 07-01-2023, 12:08 PM
  #24  
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Originally Posted by fritz k.
Yes, I already had the fan housing out with the engine in the installation situation. It's a bit fiddly because it sits low and just behind the closing panel but it is possible. The alternator is screwed onto the housing from behind and the cables have to be disconnected. If you have DIY experience on the car I would do it, otherwise leave it alone.

Fritz

Clarification. I meant the shroud on the top of the intercooler that is held in by two rivets.
Old 07-02-2023, 02:22 AM
  #25  
fritz k.
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My fault. I already had the IC shroud off, only the two pop rivets on the side have to be drilled out. The inner part of the rivet then remains in the net, you cannot get it out. To attach the shroud you need pop rivets and a rivet gun.

Fritz
Old 07-03-2023, 03:03 PM
  #26  
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Recommend not painting the shroud. Hah. If you're going to get in there, may as well replace your alternator though. . Was one of the tougher jobs I did on mine.
Old 07-03-2023, 11:20 PM
  #27  
Scott Dunavant
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Be careful not to drill through the core on the inside. It's like 7-8mm away from the outer structure on this Andial S2 intercooler shown on my 91 965. This intercooler barely fits with the shroud and tail seal.


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Old 07-05-2023, 02:43 PM
  #28  
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Oh that shroud.
Old 07-05-2023, 03:40 PM
  #29  
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I just went for it a few days ago. I was able to remove the inside nub using a rotary tool and time. This will allow me to reuse the same factory hole, after I find the appropriate size rivet.

Now to replace all fuel lines (while I’m in there) and paint the IC shroud red to match my intake I painted during an engine out.
FYI: you can see the paint results on the intake.
paint used was;
Express Paints
- guards red LM3A/L80k/G1
- aerosol clear coat
- aerosol primer





Old 07-06-2023, 09:43 AM
  #30  
Scott Dunavant
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How's your a/c clutch? My fiber disk inside the clutch was disintegrated. I need to find a new one.


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