[CBR335]

BigTom IC installed along with custom fabricated hot and cold-side aluminum piping and welded support brackets. 2009 E92 with FBO.

The Installation:
I worked with Tim at Speed Force Racing in Santee, CA on the installation. Tim is an amazing fabricator and tuner and was kind enough to let me do most of the work myself in his shop to cut costs. We worked together to decide on how to mount the IC securely and how to best rout the inlet and outlet plumbing with the least restriction and to minimize the use of silicone couplers. The solution to the mounting was to weld steel nuts to the bumper for clean mounting points and aluminum L-brackets to the IC. The IC is very securely supported by the two brackets, although I think I will add some rubber vibration dampers to the mounts later as it transmits a bit of vibration to the chassis that can be felt. The inlet and outlet IC piping was modified with custom angled pieces that clear the fan shroud and line up perfectly with the turbo outlet and charge pipe lower segment. Tim also fabricated a custom bent and welded lower charge-pipe segment to replace the stock piece of crap and bead blasted it to perfection. Overall, I am very pleased with the results even though the materials and labor cost me more than the $300 for the IC. In the end though, I have a one-off custom IC setup that I am very happy with. Not as cheap as I could have done it, but very clean in the end.

I also want to add that I was talking to Michael at ETS about a custom race core with similar dimensions and a higher quality core. Unfortunately I had a deadline and a strict budget for my project I had to meet, so I couldn't go that route for now. Undoubtedly, ETS could produce a better IC with the same dimensions for more money along with the hardware that I had fabricated from scratch. Remember there is more to the project costs than the IC alone and this is something that the budget shoppers don't always take into account.

BigTom IC installed


From the top showing custom mounting brackets


Modified BigTom IC with custom hot and cold side pipes



Inlet and Outlet Piping

[Enicinitas]

Good job bro! Looks solid.

[CBR335]

Originally Posted by Enicinitas

Good job bro! Looks solid.

Thanks! How is your car bro? We have got to get down to the track together. I ran the BigTom-IC at Barona on Saturday with Supahdave and had a personal record track day even in 90 degree heat and a 4000 ft DA! I think that we're gonna race at Barona next time as well.

[Enicinitas]

Should have it this Wednesday. We'll see, I'll call you when I do get it and hopefully I can learn a thing or two about racing from you guys as well.

[Bakeme521]

I like the custom piping, but can you use the stock piping with just the right silicone fittings?

[Big Tom]

Originally Posted by Bakeme521

I like the custom piping, but can you use the stock piping with just the right silicone fittings?

Yes you can. I have done it, and it works very good.

[335xiRT1]

Nice install. Looks good.
Looks like 335 has a little more room to play with the the 135.

[Ferre86]

wow! good job there!

[cn555ic]

I love the fact that you added to brackets to the intercooler to secure it! So much better than the zip tie method thats for sure!

[techlogik]

That looks to be a pretty simple weld setup with the nuts and bracket...take no time for someone with basic welding to get that done. Plumbing is way more complicated with the welded piping you did.

Silicon and 60-45 degree connectors, a few join pieces of aluminum and some extra silicon to cut to fit would have been fine. It is nice having a solid weld on the connector...only problem I could see is any flex in the chasis and the connector is too rigid the way it is attached, maybe causing wear on those bracets and piping weld joint.

I think the rubber grommet idea on the intercooler to allow a looser fit so it can flex/move is a good idea for this. That would alleviate any flexing of the bumper/chasis plumbing mount points.

Great stuff!

[Bakeme521]

Originally Posted by techlogik

That looks to be a pretty simple weld setup with the nuts and bracket...take no time for someone with basic welding to get that done. Plumbing is way more complicated with the welded piping you did.

Silicon and 60-45 degree connectors, a few join pieces of aluminum and some extra silicon to cut to fit would have been fine. It is nice having a solid weld on the connector...only problem I could see is any flex in the chasis and the connector is too rigid the way it is attached, maybe causing wear on those bracets and piping weld joint.

I think the rubber grommet idea on the intercooler to allow a looser fit so it can flex/move is a good idea for this. That would alleviate any flexing of the bumper/chasis plumbing mount points.

Great stuff!

Have you ever welded on aluminum?? Not easy, def. requires skill. I would have to pay someone, I'd be worried to weld on my new intercooler. OP, if you welded all that yourself, great job b/c the welds look great. But I agree with you on some rubber grommets to help make it a little more flexible.

[CBR335]

Originally Posted by Bakeme521

Have you ever welded on aluminum?? Not easy, def. requires skill. I would have to pay someone, I'd be worried to weld on my new intercooler. OP, if you welded all that yourself, great job b/c the welds look great. But I agree with you on some rubber grommets to help make it a little more flexible.

LOL, I definitely didn't weld that myself. Tim at Speed Force Racing did the welding and he has 15 years of welding experience. Yes very basic stuff, but it required a lot of test fitting to get the angles and lengths just right. As to the mounting points, I agree that chassis flex and vibrations could cause breakage of the brackets and this is something I'm going to address with some improvements. The hot side piping is also very difficult to connect due to its regidity and the limited space for IC movement during installation, so I will probably modify that as well. For now, it as working amazingly well.

The average DIYer could simply use silicone couplers and short pipe segments just like BigTom and others have done and more cheaply than my project. I just like to do things differently.

[CBR335]

Originally Posted by Big Tom

Yes you can. I have done it, and it works very good.

The setup that Big Tom and R1000K3 used to plumb the IC is just fine and gives you the flexibility to use the stock or other charge pipe sections. I tailored mine to fit my needs. I'm sure the performance differences won't be significant with my setup if any.

[E92murdered]

how did you and dave do at barona?

Originally Posted by CBR335

The setup that Big Tom and R1000K3 used to plumb the IC is just fine and gives you the flexibility to use the stock or other charge pipe sections. I tailored mine to fit my needs. I'm sure the performance differences won't be significant with my setup if any.

[CBR335]

Originally Posted by E92murdered

how did you and dave do at barona?

Not too bad. DA was 4000 ft and the temps were 85-90 degrees, but I did alright. We need to go back when it is cooler. Here is my best slip on nitrous......Dave is in the left lane:

[645Nm]

Wow...that IC is a monster Well done and great pics. The install seems easy enough and no major trimming of the bumper....i like how it is also secured at the top

[mycoupe]

I'll post it here again for those that don't see the other 2. Here is what you need if you aren't doing the hard pipes. Also, this is for those in North America.

[BrianMN]

Didn't see this posted first time around. The OP did a very good job..a lot better mounting bracket than Zip Ties. This is a legitimate fit..good work!

[Rotorocious]

Does anyone have any pics of the engine after this install?
I"m primarily looking for pictures of the piping where the turbo out let is and where the piping meets back up to the throttle body side.
I've only seen intercooler area pictures so far.

[NiVeDh]

[halkordy89]

i just got mine cant wait to intall it this week

[PASE624]

anyone know where exactly i can purchase big tom IC from??