5.0 Twinscrew Installers - Grinding Front Cover

[S197 GT]

I'm lost.. thats what I got from prochargers website. I guess it makes since.. I think they have 2 versions of intercooler for our cars.. I'm not sure which one I have.. haha



Cool looks like you have someone that can get access to tools you need. I dont know if you still have contact with mikey, but it would be fun as hell if he was there too.. haha


make sure you have a big can free.. hahaha

Yeah 2 different intercoolers. The H.O. Kit's intercooler is ridiculously small. Nobody should run the H.O. Kit. American Muscle has the Stage 2 kit even cheaper for some reason!

I've contacted Mike, but haven't heard back from him. He's married with a new baby, and he lives in Sonoma now. I hope he makes it, but I don't think he will.

 

[19COBRA93]

I'm lost.. thats what I got from prochargers website. I guess it makes since.. I think they have 2 versions of intercooler for our cars.. I'm not sure which one I have.. haha

Both intercooler versions require cutting of the inside of the bumper cover. The HO kit requires less cutting because of its pathetic intercooler, and the stage II kit requires nothing short of a chainsaw. But the stage II intercooler is so massive, it's worth it. When Procharger says "minor cutting", they really mean moderate to actually weight savings cutting.

Either way, it's still easy work, and nothing to the extent of the grinding required here.

 

[TimMcc]

I thought the grinding was easy. Child's play really, nothing hard about it. Just grind. Sweeping the dust up was the hard part cause the broom gave me a splinter.

 

[KJGT]

Hell, I didn't even know about this step until someone told me "good luck grinding the front cover".

Anyone who says that never did it, it takes 10 minutes if that with a 4" angle grinder. Any metal grinding wheel will cut through the aluminum like butter.

Biggest PITA for me was cleaning up the dust.

 

[Turbo 6]

I think people tend to overthink this. Like Kevin said, a 4" grinder makes quick work of this. Just make sure you keep checking for clearance before you clean everything up. There was a little spot left after I cleaned everything up, had to make another mess.

 

[lostsoul]

I've contacted Mike, but haven't heard back from him. He's married with a new baby, and he lives in Sonoma now. I hope he makes it, but I don't think he will.

I told him to keep it in his pants!.. He probably is the mod of some mini van forums.. haha

Anyone who says that never did it, it takes 10 minutes if that with a 4" angle grinder. Any metal grinding wheel will cut through the aluminum like butter.

Biggest PITA for me was cleaning up the dust.

Please Nick!!! let me do this part

 

[BlackMamba03]

you wouldnt have to grind anything on the motor if you went with a Kenne Bell set up. although you have to cut away a little on the front left fender wall........

 

[fdjizm]

go at it with this for more accuracy...

 

[S197 GT]

you wouldnt have to grind anything on the motor if you went with a Kenne Bell set up. although you have to cut away a little on the front left fender wall........

Informative first post.

 

[BlackMamba03]

Informative first post.

and why would i kiss your ass? anyway, whyd you decide on a whipple over anything else? what are your ultimate goals for the car? just street? a little track? drag?

 

[S197 GT]

and why would i kiss your ass? anyway, whyd you decide on a whipple over anything else? what are your ultimate goals for the car? just street? a little track? drag?

Check out my build thread linked in my signature for those details.

This thread is supposed to be informative info regarding grinding the timing cover.

 

[white05gt]

Damn, that looks to be quite a bit of grinding. I would probably try what 302 suggests but I would make sure I had a die grinder with a burr bit.

 

[Trbosvt]

I use a 3" Flapper wheel....the only draw back is tons of dust. But it makes for a clean job.

 

[KJGT]

Damn, that looks to be quite a bit of grinding. I would probably try what 302 suggests but I would make sure I had a die grinder with a burr bit.

It would take forever with a burr, but its doable, but you will slip most likely so I dont know how much better looking the final product will be.

If you want it perfect looking, pull off the cover and mill it down. But with the bracket on you dont see where the grinding was done. Granted if you pull the blower off to sell it you will see it and it can look pretty ugly. Mine looks OK and I was pretty careful, but its still obvious it wasnt done at the factory.

 

[white05gt]

It would take forever with a burr, but its doable, but you will slip most likely so I dont know how much better looking the final product will be.

If you want it perfect looking, pull off the cover and mill it down. But with the bracket on you dont see where the grinding was done. Granted if you pull the blower off to sell it you will see it and it can look pretty ugly. Mine looks OK and I was pretty careful, but its still obvious it wasnt done at the factory.

I didn't recommend a grinder because most wheels will load up in a matter of seconds since it is aluminum.

 

[KJGT]

I didn't recommend a grinder because most wheels will load up in a matter of seconds since it is aluminum.

I did mine with regular metal grinding wheel on a 4" angle grinder, it didnt clog at all. Its not like using a little dremel with a stone that gets clogged. I've used the same grinder and wheel to cut and grind a trans bellhousing off for an ultrabell..

 

[slagburn]

Regular air cut-off wheel. Cut little slices out of the ribs, break 'em with a hammer tap, smooth it out and you're done.

 

[S197 GT]

Finally done with the timing cover grinding!!!

It wasn't that bad at all.

I used the following;

Dremel 4000
Dremel Reinforced Cut-Off Wheels 426
Straight Edge with mm readout
Sharpie Markers

I realized that my best way of doing it is first measuring out the 20mm mark on the semi-cut boss. I put a rough mark on the remaining bosses and ribs. There are no measurements to use, so you just have to use your judgement based on the drawings.

The (2) leftmost bosses are easy to get to and really don't require any special notes to follow. The semi-cut boss will require you to remove (2) bolts on the water pump and also the cross section where the upper radiator hose meets the engine. I cut several "slices" into the boss in order to chip away at it leaving room for my Dremel. Once I had a decent amount of material removed, I ended up using the cut-off wheel in a grinding fashion. I turned it 45* and used a side to side motion to bring the surface down even and flush. It works quickly too! Much faster than cutting away at it.

I accomplished the task of grinding the front cover with just a Dremel!

 

[Twinscrewgt]

Looks killer man

 

[KungFuHamster]

cant you order the front cover already grinded down from FRPP?