Mounted the On3 IC without butchering the bumper cover - Ford Mustang Forums : Corral.net Mustang Forum
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post #1 of 23 Old 08-04-2011, 07:49 PM Thread Starter
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Mounted the On3 IC without butchering the bumper cover

When I put the On3 kit on my 92 hatch I butchered the bumper cover. It already had been modified to fit the previous Procharger IC so I didn't feel too bad. I am now installing the On3 kit on my 87 coupe. This car's pretty straight and I didn't want to butcher the cover. Besides I like the stealth look.

I was able to mount the IC in front of the AC condensor by trimming the headlight bucket, the back of the parking lamps and the inner bumper. The car is filthy but here are the pics of the bumper after the install:


By frankrpatrick at 2011-08-04
By frankrpatrick at 2011-08-04


92 Hatch On3 Turbo, T56
92 Vert 349 Lunati Stroker T5
87 Gt Eddy HCI T5
87 Notch in progress

Last edited by fmyth; 08-04-2011 at 07:52 PM.
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post #2 of 23 Old 08-04-2011, 08:00 PM Thread Starter
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These are the pieces I removed. The piece on top was removed from the headlight bucket. The two yellow pieces were removed from the bottom of the inner bumper. The two blue small pieces at the bottom of the first pic are the only pieces removed from the bumper cover.


By frankrpatrick at 2011-08-04

This shows the piece I cut out of the headlight bucket. My engine was out of the car so I pulled the ac condensor out of the way and set the IC in place. I used a sharpie to outline it and then a small air cut off tool to make the cuts.


By frankrpatrick at 2011-08-04


92 Hatch On3 Turbo, T56
92 Vert 349 Lunati Stroker T5
87 Gt Eddy HCI T5
87 Notch in progress

Last edited by fmyth; 08-07-2011 at 09:00 PM.
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post #3 of 23 Old 08-04-2011, 08:11 PM Thread Starter
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More pics:

















92 Hatch On3 Turbo, T56
92 Vert 349 Lunati Stroker T5
87 Gt Eddy HCI T5
87 Notch in progress
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post #4 of 23 Old 08-05-2011, 11:13 AM
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Wow, that looks great! I really wish I would've seen this a year ago, before I cut up my bumper to squeeze the i/c behind the cover while keeping the a/c. The cover still doesn't sit quite right. I may have to pull it off and try this trimming. Though, I'd have to figure out if it'll work with the routing of my cold side pipes.

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post #5 of 23 Old 08-05-2011, 07:13 PM
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This is good to know. I like keeping my pretty stealthy too but my IC hangs to low. I need to get another bumper cover anyway when I start on the exterior. After moving the IC, I would just need to hide my boost and AFR guage for a completely stock look. My exhaust is really quite so it surprises everyone I take for a ride.

Last edited by scoates; 08-07-2011 at 01:09 PM.
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post #6 of 23 Old 08-06-2011, 04:10 AM
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That's the best one I've seen for mounting the ic. Nice little write up!
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post #7 of 23 Old 08-06-2011, 01:09 PM
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very nice.


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post #8 of 23 Old 08-07-2011, 04:15 PM
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I pulled my radiator out and installed the IC from inside the engine bay. I didn't cut anything nor remove the front bumper!

Good job!! I would post picsof mine but I'm computer illiterate. Doh!

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post #9 of 23 Old 08-10-2011, 11:34 PM
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I did this same thing pretty much on my Mach. I mounted it so good, I could easily still use the stock PS cooler device.

Props!
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post #10 of 23 Old 10-12-2011, 02:27 PM
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Bringing this thread back from the dead!

What is everyone doing for intercooler brackets? Also, what size bolts will be needed to thread into the intercooler? If anyone has this info it would be super helpful.

Thanks!

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post #11 of 23 Old 10-13-2011, 01:29 AM
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awesome writeup. i gotta keep track of this.
i dont have an ac condensor and have 1 piece headlights, so I knocked alot out already. should go in pretty easy

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post #12 of 23 Old 10-13-2011, 10:00 AM Thread Starter
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Originally Posted by brady_f View Post
Bringing this thread back from the dead!

What is everyone doing for intercooler brackets? Also, what size bolts will be needed to thread into the intercooler? If anyone has this info it would be super helpful.

Thanks!
My kit came with bolts that thread into the ic mounts. I made the brackets from a piece of pipe strap I bought at home depot.

92 Hatch On3 Turbo, T56
92 Vert 349 Lunati Stroker T5
87 Gt Eddy HCI T5
87 Notch in progress
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post #13 of 23 Old 10-13-2011, 10:02 AM Thread Starter
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I pulled everything apart and painted the ic and the brackets black. Going to try to wrap it up this weekend and get it started. Will update this thread with more pics soon.

92 Hatch On3 Turbo, T56
92 Vert 349 Lunati Stroker T5
87 Gt Eddy HCI T5
87 Notch in progress
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post #14 of 23 Old 10-17-2011, 10:33 PM
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Damn that looks good!!! i choped mine up but it was trash already lol

88 coupe.
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post #15 of 23 Old 11-01-2011, 11:40 PM
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that does look good,but isn't that going to hurt the cooling it would provide with the air going thru it from the opening in the lower cover? pushed up higher,i would think the only air that's going to go thru it ,is the air going thru the smaller opening there around the emblem
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post #16 of 23 Old 11-02-2011, 12:00 AM Thread Starter
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that does look good,but isn't that going to hurt the cooling it would provide with the air going thru it from the opening in the lower cover? pushed up higher,i would think the only air that's going to go thru it ,is the air going thru the smaller opening there around the emblem
The top of the IC isn't going to get much airflow if any through the opening in the upper bumper cover (emblem area) The IC is still directly in the path of air entering through the lower opening in the bumper cover. On this car I simply mounted it in a way that did not require cutting up the corners of the lower opening or removing the small center section. There's not much you can do to get more airflow without butchering the bumper cover.

I am only running 4.5 psi so I am not too concerned about my iac temps. I suppose someone running much higher psi might be more inclined to cut open the bumper to get more air flow to the IC. The car should be on the road this weekend so I will update the thread with time slips soon.

92 Hatch On3 Turbo, T56
92 Vert 349 Lunati Stroker T5
87 Gt Eddy HCI T5
87 Notch in progress
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post #17 of 23 Old 11-02-2011, 12:04 AM
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going by the pic's, i could not tell..was not knocking you at all, sounds like it should still work fine,and i'll remember this, for when i get started on my hp kit here soon. keep us posted on how it runs
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post #18 of 23 Old 11-02-2011, 12:18 AM Thread Starter
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going by the pic's, i could not tell..was not knocking you at all, sounds like it should still work fine,and i'll remember this, for when i get started on my hp kit here soon. keep us posted on how it runs
It's reall hard to see the IC at all with the lighting in my garage. Now that I've painted it all satin black you can't see it unless you are within 3 feet and know what your looking for. If the car didn't have a cage and a cowl hood it would make a great sleeper. I am a little concerned about cooling but have installed a dual spal fan. If it runs hot, engine temps or IAC, I will move the trans cooler out from in front of the radiator. If that doesn't fix it I will prob switch to e85.

92 Hatch On3 Turbo, T56
92 Vert 349 Lunati Stroker T5
87 Gt Eddy HCI T5
87 Notch in progress
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post #19 of 23 Old 11-02-2011, 01:42 AM
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hey did you have any trouble mounting the 90* pipe from the ic to the t body? it's like mine need to be an inch longer on the t body side and 1 inch shorter on the 90* pipe to t body pipe side it sits kinda kinked up in there. it seems to work fine, my car runs awesome but that one part of it looks kinda trashy.

I'm not a magazine racer, my car is actually fast.
I also have a Honda civic but, mine has a bigger, uglier driver.
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post #20 of 23 Old 11-02-2011, 11:48 AM Thread Starter
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hey did you have any trouble mounting the 90* pipe from the ic to the t body? it's like mine need to be an inch longer on the t body side and 1 inch shorter on the 90* pipe to t body pipe side it sits kinda kinked up in there. it seems to work fine, my car runs awesome but that one part of it looks kinda trashy.
I did have an issue with the cold side pipe that connects to the TB. I am running an AJE K member which positions the engine different than the old QA1 that I was running. The new K member combined with moving the IC up about 2 inches higher created some challenges installing the cold side. I had to experiment with moving the IC left to right a few times to find the sweet spot and then had to buy a 3" piece of tubing and a silicone coupler to extend the pipe that connects to the TB. I will try to post a pic.

92 Hatch On3 Turbo, T56
92 Vert 349 Lunati Stroker T5
87 Gt Eddy HCI T5
87 Notch in progress
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post #21 of 23 Old 11-03-2011, 09:20 PM
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looks good!!!
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post #22 of 23 Old 04-09-2017, 03:13 PM
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Where did the pics go?
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post #23 of 23 Old 04-14-2017, 01:23 PM
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this thread is from 2011, picture links were hosted externally.
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