KZ-TE Cirrus cooled

[JohanW]

A couple of weeks back i decided to take the leap and order a cirrius inter-cooler after all the positive responses about said cooler on the forum. Big thanks to Andre (Dodging) for the pics and writeup. This helped a lot in the installation and decision.

So here goes. Costs involved:
Front mount Cirrus intercooler: R4350
courier cost: R340
Black silicone gasket maker R60
76mm bi-metal holesaw R122
3m cutting fluid R76 (this is essential)
some cable ties and washers

everything else comes in the box.

This is not a quick Saturday afternoon job you can do on your own. Grab a friend and book a full day to do the work.

Cutting fluid is also essential otherwise you will just dull the hole-saw and not make any progress. the ifs steel is much harder than the sfa's...

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[JohanW]

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[JohanW]

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[JohanW]

Problems encountered:

Hiluxs dont cut easily. I dulled my father's 76mm hole saw on the first cutting attempt. I had to go buy a new one and some cutting fluid. The combination was awesome. it just slices thru metal in seconds.
The bumper is a female dog to refit. I had to refit the bumper by myself since my friend was not available. There was a pretty girl involved...
According to the instructions supplied. You should "slot" the mounting brackets. I decided against this. I removed the bracket from the actual bumper and inserted 1cm worth of shims/washers to space the bumper forward. Looking back, i would say this was a good route, but the spacing was too little. It needs to be 3-4cm.

Results: Tintin now pulls like a d4d, well almost...
Cruising at 120 is now effortless and hills a had to drop down to 4th can easily be cruised up.

NOW: I have not installed a chip yet. Maybe in the near future i will. (cash is a bit low now) At the moment i am quite happy to leave it as is.

Will report on consumption as i go along.

[Donkey]

Happy for you, one day when I grow up I want to be like you.
Hope you get the turbo sorted out soon

[george]

Nice.Was your buddy going diving with a pretty girl

[Donkey]

[JohanW]

george, you could say that. I had a stuck bolt keeping the bullbar on. So we whipped out the grinder and got to work. Before we could start we needed some eye protection. The only ones we could fine that fitted him were some old diving goggles.

[Dodging]

Mooi gedaan!

Lyk tjap

[Froll]

Nice job, looking good. now just need some rivits for the number plate.

[JohanW]

the numberplate holder has some rivets holding it in place. The cable ties are to keep drunk students from stealing the number plates in Stellenbosch. Its not uncommon to find a street full of cars without number plates on a Sunday morning...

I am busy drawing up plans for a full alu bush bar. So the bumper is temporary. Not going to mount a winch so alu will be strong enough.