This has been a major project, but it's so close now. Thought I'd throw out a couple pics on the plans for the intercooler. Plumbing that is about the last of it, then I can fire it up and start tuning. I had to buy a new block so got a Dart SHP stroked to 401CI. AFR 195 heads. Also changed from the 700r4 to a probuilt 4L60E with a 10 inch Vigilante TC. I had already changed it out to a Dana 44 with 3.45 gears. I figure this intercooler should flow plenty without a pressure drop. Had to flip one end tank around. I'll have to cut a hole in the hood near the front-seal it up to the intercooler and then put on a hood scoop. Planning on a 21 inch wide scoop with a 5 to 6 inch opening. Since it's 6 inch down front it won't block my view out the windshield. This project just grew as it went! Callies forged crank, JE 2618 forged pistons, all ARP studs etc. More money! I just ordered a couple of 30 degree silicone hoses to complete it-then have to make some brackets to hold it.

 

Congrats it on a very big project, now its a labor of love... I promise you when it is sorted it will plaster a smile on your face!
I hate to see you having to cut the hood. The Callaway Twin Turbos had twin intercoolers up against valve covers, I wonder if you could somehow do couple of smaller units and mount them in the same place, I know plumbing will be trick but the performance and the aesthetics may be nicer.

I have heard Callaway will not sell parts to no Callaway car owners. Looking at the intercooler you have if it were cut into would you wouldn't lose any size or capacity. I know that may be impossible but maybe a custom built one would be better. If I recall the Sledgehammer vette that boxed and and used the frame as a component.
A little outside the box lol... Keep going my friend, you are nearly there, Cheers - Jarrod

 

Why not mount vertically in front of the radiator?

 

Why are people on this forum so quick with the "What I'd do's" and "Maybe if's" when no request for suggestions has been made? The OP is near to completing a major and difficult job and decided to share his work successes. While it is always risky to assume, I would think that if the OP has the skills to accomplish the above task, he(they, them, he, she,....) has done a fair amount of research and reached a decision on what was to be done. Would some suggest the work all be torn apart and redone THEIR way? Complimenting one and then telling them what they did wrong is tantamount to a doctor saying "Your broken leg is healing nicely but you have cancer."

 

I was just curious about the rationale behind the decision. Many other kits mount it vertically. The work he’s going to do to the hood is no easy task.

He clearly has the skills to do what he wants, I like to understand paradigm and don’t really care beyond that. It’s his car.

 

Hi everyone-to explain how I got there on the intercooler-if I put it in front of the radiator (and it would have to be smaller) there is no way to run the AC in the summer without overheating, or even get stuck in traffic on a hot day. And it already has oversize aluminum radiator, dual Spal fans and the xtra pusher fan in front with a trans cooler. Temps here will get over 100F. News just said Palm Springs area will hit 121F!!!!! I have to deal with smog-the supercharger has an EO number and it has to have an air to air intercooler on the front of the car. So this is the closest I could come up with to fit a good sized intercooler at the front of the car. And it says Procharger right on it. One of the Procharger intercoolers for the C4 sits over the radiator and would take air thru a hole where the air filter used to sit-so I'm just redirecting airflow to it. Have to deal with EO requirements.....and still make it work. I had looked at air to water also, but it says specifically it has to be an air to air. Yes, I'd prefer not to cut up the hood-but I already have to put the vents over the wheel wells in it-and they do let a lot of heat out. Everything done to it is functional-not for "looks". Once I get the part throttle tune done and pass smog, then the fun part-I'll take it to a dyno for WOT tuning. I'll stay conservative on spark and AFR and see what RWHP it puts out. It's a fun hobby for me, just an old hotrodder!

 

You made me laugh with the they, them etc-I can't keep track of all that ever changing stuff. I'm just an old fart "he" LOL! And no worries on the questions out there-I figure if I can explain how I got there and it helps out someone else on their project then it's all good. Wrench on!

 

Thanks it is a massively thick intercooler and I suspected that was the issue but wasn’t thinking about the A/C.

good stuff!

power expectations?

 

I'm hoping for 600+HP. I know the cam would add HP if I could go bigger, but if you pull in for a smog and it's got a lope to the idle they'll tell you to go away.

 

Congrats again. I'm researching turbo builds for my 95. Yours actually seems like the most in line with how I would like to build mine; the least amount of relocation as possible.

Could you please do an in-depth photo tutorial of what and how you did your plumbing?

 

With the IC placement it's pretty simple I used clay and aluminum bars bent to the shape of the hood to figure out where the hood will sit in relation to the IC. The difficult part will be cutting the hood tight to the IC so that a strip of weatherstrip will seal up between the hood and the IC and the silicone pipes coming off of it. There are mounting tabs under the IC that I still have to make mounts for. The core is 18X6X3.5.

 

Appreciate the response. That's already very helpful. Thank you!

Which headers did you use? Where did you find your parts? It looks like STS (Holley) recently stopped selling their turbo kit, and even though I do not want to do rear mount, it was a good place to start.

It's been frustrating reading through the annals of forums only to find chatter from a ton of people like myself talking about what they want to do or what they might do, but then crumbs on how people actually did what they wanted to do!

You're a rarity for a recent (successful) forced induction build!

 

If you're planning a turbo build instead of a supercharger like mine you've got a lot more plumbing to plan. If you can weld then you could fab the headers yourself for a turbo. Although the kits alone can run $1000.00. It's all expensive! There used to be a dedicated forced induction C4 forum here, but it's merged now. Just seems there's less interest/posts on the C4 when it comes to tuning and FI, but there are still quite a few folk here that can help you out that have done turbos and supercharger builds.

 

Well I ended up getting the bottom about 1/4 inch off center. But it's not going to visible once a hood scoop is on it. Yup, can't help but cringe when you first start cutting up the hood! I've got a 6 inch scoop ordered and may go to a 4 inch-have to wait and see on that.