so today i decided i would cut some sheet metal <img border="0" alt="[Satan]" title="" src="graemlins/satan.gif" /> and make way for the ford intercooler for the 7m motor. i have a few questions about how to go about and brace the front end. i had to cut the front body mounts to make room for the intercooler to fit in under the hood. and in for the bumper and such. <img src="http://members.aol.com/evileyzclothing/images/frontminusbm.jpg" alt=" - " />

in the red is where i cut. i don't think i will have use of my hood latch unless i can fab somethign up. i don't think there is room. so i will probably end of using hood pins
:\

i'm thinking there will be enough room to mount the to push fans i have on the front of the intercooler and still modify my grill to fit back on.

what do you think i should do about front body support.

thanks ryan also here is the site with some more pictures.
website

<small>[ April 28, 2003, 04:03 PM: Message edited by: ryno ]</small>

Ryan,
I see you have already done some cutting. With my swap, I wanted everything
under the hood and behind the stock grill. I didn't want hood pins so I had to
keep the stock latch, plus I wanted to retain the stock inner fender wells.

One thing you can do is to cut out the inner wells and core support and build
all mounting supports with tubing (the way the desert racers do).

If you want, you can come over and see what I did. The only problem I can see
is that you've cut out more than I would have.

DOH!! i'm not tooo worried about it .. i wanted to do minimal cutting.
but buy a couple of 20 packs of bud and give your frineds salzalls and grinding/cutting disks.. this is wht i got..
i have more pictures. i will post them on my site later today.

i didn't see a way that i could not cut what i did and still fit the intercooler in far enough to still be able to mount my grill. this is on an 85 yours was a 94 correcT? i dunno if that makes a difference.
i'm more worried about the spring perches.. i think that they are weaker now and need to brace them.
as far as the fenders i think i'll still have to cut some more to be able to fit the bent tube in there. i don't see how you cut less.. but i would have loved to keep the stock hood latch. i'm stil trying to work out maybe a bracket to still fit the hood latch.. but i don't see it happening. do you have pictures? close up of the latch and than each fender well?

thanks

ryan

Ryan,
Actually, my Runner is an 85. I basically cut the center section out of the
core support, straight down thru the front x-member (the width of the
frame rail spacing. This left the front body mounts in place. This allowed
me to mount the radiator lower and more forward). Take a look at my
pictures, it may give you some ideas:
http://www.hpphoto.com/servlet/com.hp.HPGuestLogin?username=bobgoya&password=62188403

Pic #8 shows how I cut the bottom of the radiator support and front frame
x-member. I also notched the frame to fit the radiator between the frame
rails. I used 3x3 angle iron and welded it across the front of the frame
rails. This provides the x-member in front and the angle portion protects
the bottom of the radiator (one of Advanced Adapter's ideas). I welded
all my bumper brackets off the angle iron.

Pic #6 shows the radiator in position.

Pic #11 shows how the radiator fits under the removable support section.

Pic #12 shows the hood latch with a modified bottom support bolt hole.

ford powerstroke intercooler setup this is another thread.. adn i'm actually copying him.. i cut the brackets off the intercool they stuck up above the hood. i also lost the hood latch i dunno for some reason i think he kept his.

BOBG i think you put something different in your truck.. you don't have an intercooler correct? not cutting as much as i have wasn't an option.. as you can see it barely fits now.

i'm looking for advice on how to brace what i have left unbraced. my bggest concern is the leaf spring perch where i cut thebody mount.. i was figuring putting a clat peice in there parallel to the hanger and weld it up. than fab up a mount for the intercooler. put some weather stripping anywhere and everywhere i can. and cut out some rubber to sheild the motor compartment from water.

now in the process of removing my radiator i found what seams to be a inline water cooler. i don't see that in any of my FSMs so i dunno where it came from.. its u shapped 1 1.5 in dimeter and is connected inbetween my thermastat and turbo.maybe to cool the water afer the turbo? i dunno.

maybe there is no need for this?
maybe there is a better one?
i'm hopeing i can fit it inbetween the intercooler and radiator. maybe i'll stick it under the two. i dunno.

i would like pictures from anyone who has fabbed up body supports for the front. and if anyone knows where to get mandral bent 3 in aluminum in so cal.. or anywhere for cheaper than 50 bux a bend please let me know

thanks

ryan

Ryan,
Wow, that intercooler is HUGE!! I had no idea.
You should have Rob (SuperRunner) take a few close-ups of
his mounting. The last time I saw his Runner, he had the smaller
intercooler. I think he's using just hood pins and not the stock
latch.
You can try Bassani for the mandral bending, but I don't think
they will be less than $50/bend.

Just as a side note: If you plan to eventually go with a Hysteer,
now would be a good time to plan for it. I'm getting ready to do
mine and find that I've got my radiator real close to the stock
steering box and may need to relocate it to fit in the new IFS box.