Finally I could make the intercooler mounts after the rad frame project had progressed to this point.
Rubber mounts on every four corners of the I/C. I also have hump hoses for both inlet and outlet tubes,
so the I/C should be safe from vibration damage!
Lower mounting brackets:
Safely in place!
(on top left you can just see the modified top part of the frame that allows for the vibration insulated top mounts for both sides of the I/C)
A perfect fit!
Looking good from this angle too. Almost 100% of the core is in direct air flow through the grille.
I will make some aluminum air guides to perfect it, but now I'll just try to get the support frame done.
Then the I/C brackets had to be bended somewhat for them to double as supports for the oil cooler and the fuel cooler.
Upper mounting brackets for the aforementioned aux coolers:
So here's how the auxiliary coolers will be mounted:
...resulting in this:
I think the big radiator is not a bad move after how I have mounted the I/C and aux coolers. As a matter of fact, I think all of the cooling
air that reaches the radiator, has already gone though one of the other coolers. This is of course what I am trying to achieve - maximum
cooling effect for the I/C, oil and fuel coolers - but this will require more of the water radiator.
BUT, the Passat TDI radiator is exactly the solution I need.
I'll update more soon, meanwhile - feel free to comment!