[scalbert]

Hopefully we can take a diversion from the bantering which it appears some understand and other do not. But in the interest of helping the whole community I will attempt to document this weekend’s rather lazy installation of RR catless DP's and the Helix Intercooler. I started removal tonight and will finish up in the morning/afternoon.

I'll start with getting the car up in the air. I have done this several times on multiple vehicles and it always seems to work out; at least no car has fallen on me yet. Here is my recently fabricated and expensive ($20) underhood illumination system.



For raising the vehicle, the front is on jack stands and the rear on ramps. I initially used the floor jack to raise the front of the vehicle enough to place a ramp under the front passenger side wheel. I then was able to get the floor jack under the front of the vehicle to reach the center cross member jack point. Once up the jack stands were placed. I then jacked the rear up and placed the ramps under the rear wheel.

Total prep time; 5 minutes.



That white rag stuffed into the IC piping to prevent any critters from crawling up.



Next was the time to remove the OEM intercooler. I left the bumper on and popped the lower IC pipe coupling retainers off using a small flat head screw driver. This is fairly straight forward and simple. Next, just remove the two screws on either side and the IC should be loose (I was actually missing one of the screws) and will slide out.

The factory intercooler hoses are retained to the upper pipes by non-screw or crimp clamps. They must be compressed on the pipes at the factory as they are a solid ring. To remove them I used a Dremel with a cutoff wheel but unfortunately had a small accident. I was at a wrong angle (and a few beers deep) to see that I slightly cut into the coolant line that runs to the expansion tank. It trimmed the outer sheath and slightly cut into the rubber hose but not much. It would probably be fine but I will run a clamp around it to keep it from expanding. If it does eventually leak I will just pop in a coupler.

Total removal time, 20 minutes.

No IC



OEM Hose Clamps showing the cut made:



And my mistake:



I decided to leave it there and finish up in the morning as my daughters wanted to play a game. They also want to help in the morning as well but my wife isn't too keen on 5 year old twin girls getting under the car. My argument is that their hands can fit up into tight spots easier.

Anyway, below are the product pictures before the installation. I will get images along the way tomorrow and post them. But for now, and after about 6 or 7 more beers, I'll hang it up until the morning. I will take some pictures of a new project as well which will be easier to illustrate rather than describe.

Old and New IC's



RR Catless DP's

[5soko]

haha awesome pics, can't wait for the rest. Love these kind of write up's!

[lyjw88]

nice pics!!
I hate it when ppl post their DIY process and the pics are all blurry or out of focus.

[scalbert]

Originally Posted by lyjw88

nice pics!!
I hate it when ppl post their DIY process and the pics are all blurry or out of focus.

I'll try to be clear with them. Since I am taking my time and allocating the entire weekend, I can make sure I get adequate images. Now the next time I install something like this for a fellow enthusiast I will be on the fast track and without beer until finished.

[lyjw88]

Originally Posted by scalbert

I'll try to be clear with them. Since I am taking my time and allocating the entire weekend, I can make sure I get adequate images. Now the next time I install something like this for a fellow enthusiast I will be on the fast track and without beer until finished.

These pics are already good!!
I think you have a pair of iron arms lol
My hand shakes like crazy when I take pics indoor, maybe I should quit smoking ASAP

[SfValley335i]

I just had my Helix IC installed the other day, you will definitely feel the power up top. I havent had the chance to test it in hot weather....

[DrewKo]

Nice! Got your message...I'll check in with you tomorrow...I'm still at the office working (that's why I'm on this stinking site) because I'm going out of town and have to have everything buttoned up. Anyway, very exciting man!!!

[ontopofm]

can you post pics of where you jack the front? that will help for my install next weekends (rr dp and motorwerks ic), thanks for making another diy, i'll definitely use this

[scalbert]

Originally Posted by DrewKo

Nice! Got your message...I'll check in with you tomorrow...I'm still at the office working (that's why I'm on this stinking site) because I'm going out of town and have to have everything buttoned up. Anyway, very exciting man!!!

Wow, you are working late. We need to set up a VPN for you so you can get some things done from home...

[scalbert]

Originally Posted by ontopofm

can you post pics of where you jack the front? that will help for my install next weekends (rr dp and motorwerks ic), thanks for making another diy, i'll definitely use this

Will do.

[M_M]

nice pictures man, can't wait to install my helix i/c soon. Did you purchase it from the GB?

[Alex@AKMotorwerk]

Thanks for the write up on the Helix FMIC... will be doing my install in a few weeks

[JB335]

So glad you're making this thread man I'll be installing my AR dp's soon as well. They came in the mail today

[Adam@Riss Racing]

Can't wait to see this install! Scalbert is a big part of this community and I know this DIY will help tons of people. Let us know if you need any help during your install.

[gt3fever]

1 brave man to install dp on your own

[pander5]

Awesome documentation and thanks for sharing this. I'm waiting for the final process and will use this very shortly.

BTW, incredible attempt at testosterone logic here:

"My argument is that their hands can fit up into tight spots easier."

My problem is that it is usually countered by estrogen logic with extreme prejuduce!

[JDLM]

I am going to be spending a nice chunk of change in June

[scalbert]

Originally Posted by M_M

Did you purchase it from the GB?

Yes, I was late to the GB but got it in earlier this week and they arrived yesterday.

[scalbert]

Originally Posted by Adam@Riss Racing

Can't wait to see this install! Scalbert is a big part of this community and I know this DIY will help tons of people. Let us know if you need any help during your install.

Thanks Adam, shouldn't be an issue and looking forward to finally having them on the car after sitting on the bench for so many months.

[scalbert]

Originally Posted by pander5

BTW, incredible attempt at testosterone logic here:

"My argument is that their hands can fit up into tight spots easier."

My problem is that it is usually countered by estrogen logic with extreme prejuduce!

I rarely wins these discussions but always need to make my case.

[scalbert]

Just FYI, I haven't gotten much done today as I was tied upt his morning and then did a V3 install for a local. But what I have done has taught me that there is significant trimming needed for the Helix IC. I beleive I have it done but still need to clean up the edges. I should be able to wrap this up tomorrow as we have an event to attend this evening.

And yes, I have taken pictures of the needed trimming.

[Rugs]

Looking forward to the pics since an IC will probably be my next mod.

My DP's were installed with the help of a friend with a lift & it was a Pain, so Big-Props to ya doing it on floor jacks!

Shoot me a pm sometime if you local BMW guys get together, I'm over in Duluth.