INSTALLATION INSTRUCTIONS
STEP 1:
NOTE: The Intercooler must already be installed.
Place the square ring in position over the intercooler and between the intercooler mounting plates. The biggest flange goes to the front flat side toward the intercooler.
If you have one with black foam on it (1st couple of kits) remove the foam as it is too stiff and will not compress. It needs to be replaced with white open cell door sealant from a local hardware store.
Compress sealant till you have enough room to pick up the four outside holes in the mounting brackets and have room for the four #6 anchor nuts. Clamp in position and drill with #40 to hold these in position. Cleco as you go.
NOTE: There should be a slight space above and below this for the box lid to fit when in the correct position.
Remove square ring after drilling.
Place the square ring in position over the intercooler and between the intercooler mounting plates. The biggest flange goes to the front flat side toward the intercooler.
If you have one with black foam on it (1st couple of kits) remove the foam as it is too stiff and will not compress. It needs to be replaced with white open cell door sealant from a local hardware store.
Compress sealant till you have enough room to pick up the four outside holes in the mounting brackets and have room for the four #6 anchor nuts. Clamp in position and drill with #40 to hold these in position. Cleco as you go.
NOTE: There should be a slight space above and below this for the box lid to fit when in the correct position.
Remove square ring after drilling.
You can fill the 4 holes with sealant (yellow line).
NOTE: The box is shown incorrectly in the picture above as it is on the top side of the square ring (red Line).
NOTE: The box is shown incorrectly in the picture above as it is on the top side of the square ring (red Line).
STEP 2:
Place box in position. You will need to trim the box and the tops of intercooler mounting brackets to allow it to slide into place to line up the side 4 holes. Position the square ring with the box installed. Cleco all 4 positions. You may have to reach in the round hole to position square ring.
Remove one of the above Clecos and drill with a #27 drill bit. Place screw in hole to position it if you do not have the correct size cleco. Continue for the other 3 holes. Disassemble and deburr holes.
Install the anchor nuts on the inside of the square ring. Countersink outside of ring (8 places) for rivets. Use a parallel jaw pliers to squeeze the rivets.
Remove one of the above Clecos and drill with a #27 drill bit. Place screw in hole to position it if you do not have the correct size cleco. Continue for the other 3 holes. Disassemble and deburr holes.
Install the anchor nuts on the inside of the square ring. Countersink outside of ring (8 places) for rivets. Use a parallel jaw pliers to squeeze the rivets.
