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Probably too late but you don’t want to cut the lip or anything on the ICs to make them fit Paul. The lip is there to create an air gap. I have a set of perfectly modified ducts that go on the 7.2 ICs for a plug and play install. They are collecting dust..
In the middle of this install right now. Be aware that the youtube video shows these being installed in a 997 turbo. The shrouds on those cars are different than the ones on our 996's. I've trimmed a bunch from the shroud and it's apparent that I'm going to need to extend the metal clips that hold the two sides of the shrouds together too.
So I need to get some rivets and aluminum stock tomorrow and start playing around.
I modified the stock clips to work. This is a pretty big project, definitely not something you can slap on there in a morning or an afternoon. I've got everything modified to fit now, I'm going to put weatherstripping on the shrouds tonight. Then I'll finally have everything done and I can start reassembling the intercoolers and install them onto the car.
Zip ties work but it's very easy to extend the OEM straps and makes it much less ghetto for those that care about the details. Takes less than an hour to do all 8 clips if you have simple tools and a $20 rivet tool.
If anyone needs detailed pictures of how to modify the ducts for a plug and play fit with the 7.2IC, let me know. Takes about 2 hours per side if you take your time.
Zip ties work but it's very easy to extend the OEM straps and makes it much less ghetto for those that care about the details. Takes less than an hour to do all 8 clips if you have simple tools and a $20 rivet tool.
If anyone needs detailed pictures of how to modify the ducts for a plug and play fit with the 7.2IC, let me know. Takes about 2 hours per side if you take your time.
Fair point, I hadn't thought of cutting the existing clips in half to extend them. That's a nice looking solution!
John, can you send me the pics? I'm going to put together a DIY thread and the pics would be helpful, thanks!
Got the shrouds and intercoolers assembled last night. Need to put the brackets on, then install them into the car and put the car back together.
Hey Josh. I just looked on my computer and realized I had deleted all the picture a few months ago when I got a new laptop. Maybe Paul can take pictures of my modified ducts since he as them or I can do it when he returns them.
I finally tracked down the pictures missing from the original post... Photo credit of course to Earl3, I am just reposting the lost images.
I've also noticed in scanning all the 'RS intercoolers in 996 Turbo' threads that I could find that there are a few different techniques for doing this, YMMV.
Originally Posted by Earl3
Duct mod write up:
Standard disclaimer -I assume no responsibility if you screw up your car, what worked for me may not work for you. These duct mods are non-reversible.
The write up is for getting the factory passenger side 996tt ducts on a passenger side 997.2 intercooler. The driver's side is the same process, but it’s a mirror image type thing. Having the intercooler in front of you while you’re doing this will help you understand the steps! If you have questions or something doesn’t make sense, just ask. This is one way to do it, other’s may see a better way.
Stuff you'll need:
-Dremel tool with a cutoff wheel & 120 grit sanding wheel
-Rivet gun (I used an Arrow RH-200 that’s like $15 at Lowe's)
-1/8" short rivets (I used Arrow RSS 1/8IP) –note, you could get by with zip ties here, but rivets seemed like a more robust option
-6"x18" 0.025" thickness Aluminum sheet metal (I used Steelworks Hillman #11232 from Lowe's)
-RTV sealant (gray or black preferred)
-Rubber Weather stripping (I used 2 packs of MD 01033 from Lowe's -you could use the RTV here in a pinch)
-Zip ties (I used GB 14" plastic cable ties from Lowe's)
I've assumed that as this point you've gotten the bumper removed, intercoolers off of the car and out of their frames (see Renntech.com spark plug DIY writeup for info here). Go ahead and release the metal duct straps & remove the ducts from your stock ICs. Give the ducts a GOOD cleaning.
Thanks Pfbz, the photos went down almost exactly when I got my intercoolers and started this mod. Going from memory I pretty much got it right but there are a few steps that I’ll take a look at again the next time I have it apart.
11-12-2019, 11:37 AM
