Replacing Evo 3 Intercooler

Hi guys

I've just bought a replacement intercooler and was told it is a direct swap.
It has these 4 screw hole things that doesn't exist in my current intercooler (circled in yellow). I've also taken a close up pic of it.
Can I just leave these or do they have to be sealed? If so, then with what?

Also, my existing intercooler have these brackets on the bottom left & right sides to mount them onto the chassis - but the new one I bought does not.
I've taken a few pics to show you. My question is can these be removed from the old intercooler and screwed/welded/whatevered onto the new intercooler?

Thanks

The 4 things which you have circled are used for mounting the cooler. They do not need to be blocked/sealed.
You can make your own brackets which you would bolt onto those holes to mount the cooler.
If you were going to remove the brackets from the old cooler I wouldnt advise screwing them to the new cooler as then you will have holes that will need to be sealed.
Why are you replacing the original cooler anyway?

The fiberglass bumper has been rubbing against the bottom right of my current intercooler and its now created a VERY small hole. I pathed it up with liquid nails but I fear that may have been worn out now also

Fibreglass has rubbed away alloy? Wow strong fibreglass

If u were close by I could have grabbed a spare evo cooler off me, I think I have 4 spare here somewhere

Thats insane....fibreglass rubbing through Aluminium!!

You want to sell your old cooler? If so PM me? I will grab it off you.

Couldn't you just get the small hole repaired? Or is it in the core itself?

Probably could get it repaired...but I've got a brand new one, might as well use it.

it's not as farfetched as it sound aluminium is soft as heck

evo-gsr said:

Thats insane....fibreglass rubbing through Aluminium!!

You want to sell your old cooler? If so PM me? I will grab it off you.

Click to expand...

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evo-gsr said:

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Click to expand...

Sorry mate, someone's already asked me to sell it to them just before you replied on this topic.

evo-gsr said:

Thats insane....fibreglass rubbing through Aluminium!!

You want to sell your old cooler? If so PM me? I will grab it off you.

Click to expand...

I've got one for sale:
http://www.4gtuner.com/topic/21141-for-sale-evo1-3-intercooler-evo1-swheel/?hl=intercooler

It should be pretty (very) easy to make up some mounting brackets for that intercooler without having to butcher your original one - the way I see it you have two ways of mounting it up:

1. Get a length of alloy angle (Bunnings sell 1m lengths of it) and use two lengths cut from it to pick up the lower mounting points using the top (horizontal) face of the angle and the vertical face of the angle to pick up the mounting points on the radiator support panel. Easy as cutting the lengths, drilling 2 holes per length and to finish it off nicely putting the rubber grommets from the stock intercooler in the holes you've drilled.

2. Just use two alloy straps (again - Bunnings....) to pick up the two lower mounting points in the 'cooler and then tek-screw the other end of the straps into the bottom of the radiator support panel. Easy as bending the straps to get the profile right, drilling one hole per strap and running at least 2 tek-screws in the other ends. Personally if it was me I'd use threaded nut-serts in the radiator support panel and some nice dome headed bolts as I hate tek-screws.

It looks like you have the centre upper mounting point which picks up the stud on the radiator support centre strap, so that should make it easy to locate the intercooler and get your lower brackets right.

"Get a length of alloy angle" - Would aluminium sheets from Bunnings suffice?

I think using sheets would create more work for you but if you can make it work then I'll be keen to see how you do it. I'm lazy so I always look for the easiest way of doing things!

i know on my coupe when fitting an intercooler like this there were two holes in the rad support that lines up ery well with the intercooler mounts. a long bolt and washer combo and some alloy strip had the lower mounts sorted. for the top i drilled through the reo. and bolt straight to the core. however yours will likly be different in the upper mount

After much grinding, drilling, cutting, I've decided to put my stock evo 3 intercooler back.
The new one's holes for the hoses were too big and when I went and put new silicone hoses in they just kept leaking boost.
Oh wells, at least I tried - couldn't have known it wasn't gonna fit if I didn't give it a shot.

Funny thing is, despite the VERY small hole in the stock intercooler, its still holding boost.
Guess Mitsubishi knows how to make robust performance parts


Anyone want a free aftermarket intercooler?
Hahaha

Spewing you couldnt work it out. If you get an Epoxy glue called Liquid Metal you should be able to patch the hole in the cooler with that. Its made by Davcon. Its a 2 part affair which you mix together, apply and let it dry for a day. Used it before for a similar job a few years back. Did the trick.
PM sent also.

I installed the same intercooler the other day. Grab some 'L' Brackets from Bunnings and drill a few holes. Hope these pics help!