Stillen Supercharger Froozen Boost Intercooler Install

EVOHUNTER

I've seen a lot of people asking about how to install the frozen boost intercooler for the Stillen supercharger kit.

I bought this one https://www.frozenboost.com/water-to...er-p-1026.html


Supplies:

Water to Air Intercooler Radiator - 26x7x3.5

2 - 1/2 Npt thread 5/8 fittings, one straight one, and 90 degree one.

10 feet of bulk 5/8's hoses.

Coolant

Mocool

Tread tape.

First thing, youll need to flip your crash bar upside down. measure out where you want it to sit, I cut exactly 1- 1/4 " I wanted the whole intercooler to be contacted through the front grill.

Measure twice, cut once!





I didn't have my fittings in when I did my first measurements lol. So don't make the mistake I did.
put thread tape on your fittings, and screw them in.







I decided to mount the intercooler with the fittings towards the passenger side.
I did this because I wanted my cool side line to have to shortest path up to the intake manifold intercooler.
I have my hot line going into the top of the intercooler and the cool line on the bottom.



Next, pull out your die grinder/cutting tool. Cut away the aluminum your not going to need.







All done and cut





make sure everything fits properly. Mark out your holes for the tabs on the intercooler and drill them out.





I decided to paint the crash bar with VHT black wrinkle paint, Not really needed because no one will see it. I had it out, so why not right?

It was still wet in this picture, but in the end turned out great.




So there's 2 ways you can mount it, With the tabs on the outside of the crash bar or the inside. I decided to mount them on the inside, just to look a little more professional, also you wont need to cut out as much material on your front bumper.

If you mount them on the outside, all you need is 2 - 12mm x 80 grade 8bolts, 2 nuts and 4 lock washers.

If you mount on the inside, you'll need 2 - 12mm x 80 mm grade 8 bolts, 2 nuts, 4 lock washers, and 2 bolt spacers .75" that will mount inside the crash bar.

mount it all up, and bolt the crash bar back on.


You'll have to remove some material from the lower front grill. I had to remove about 1/2", I used a die grinder. took about 5 mins to cut it out and clean it up.
place your bumper on, see how much is needed to be cut away.


Hook your coolant lines back up, fill the system back up with coolant. I put some Mocool in there to help reduce heat. leave the cap off, put your car in ACC so the pump starts flowing.(make sure your drain screw is tight on the bottom of the intercooler. check for leaks at this time when you have the bumper off, and fill up as needed. (check your coolant level after a good 20 min drive, (MAKE SURE YOUR CAR ISNT SUPER HOT, USE A RAG OVER THE CAP JUST INCASE, SO YOU DONT GET HOT COOLANT ON YOUR FACE OR HANDS.)


Mount up your bumper, and enjoy the cool air

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