DSM Intercoolers

Here are some pictures of the DSM intercooler conversion that I am doing. With a good set of stock intercoolers, upgrading to DSM intercoolers may only have marginal benefit for the rest of my modifications, however as you can see from the pictures below, my stock intercoolers were in very poor shape. Many of the fins were smashed almost flat, and there was a moderate sized dent in the passenger intercooler.

I had my intercoolers converted by Drweldin on 3SI.org. The turnaround time for modification was approximately 1 week. The modified intercoolers looked very good overall. There were 3 bolts and plastic spacers also included with the modified intercoolers. This allowed for all three of the factory mounting locations to be used on each intercooler. The modified intercoolers mounted up reasonably well to the factory bolt holes. I had to try a couple of times to get all of the bolts to line up and start all of the bolts loosely, but I was able to use all of the mounting bolts on both intercoolers. As you can see from the pictures below, the oil cooler was able to remain in the stock location with a little bit of room to spare. (I've heard that some aftermarket intercoolers require relocation of the oil cooler). The modified intercoolers did not have attachment points for the intercooler ducts, so I decided to use duct tape to connect them. It looks crappy with the bumper cover removed, but it cannot really be seen once the car is reassembled. One issue I noticed is that the passenger side intercooler sits very close to the bumper cover (possibly touching it), and it also seems to sit a bit low because the underbody plastic cover sticks out a little. Once everything was reassembled and the car was down on the ground it looked okay though.

Disassembly









Stock Intercoolers

















DSM Intercoolers (unmodified)











DSM Intercoolers (modified)









Reassembly













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