Evo X Intercooler cut outs on front bumper

[Jackal]

I have put the Evo X Intercooler and UR Upper and lower pipes on my Ralli art
and have gotten the Evo X side mount license plate holder because it was blocking a lot of the intercooler. Now I want to cut out the plastic,styrafoam and support brace to feed some much needed air through the top of the intercooler that is currently blocked by the middle piece of plastic that comes across the middle of the grille area.

I want some opinions. This can be done a number of ways either leaving on or taking the front bumper cover off. By duplicating the Evo X Cut outs or simply changing to an Evo X Front end and matching support but lots of dough. I was debating sort of a Ghetto aproach by simply masking off , measuring then using a cordless drill and 2.5 inch hole saw and putting in a half dozen matched holes, being careful not to go to far once I have cut through the back of the metal support pc behind the styrafoam. I little bit of plastidip or black spraypaint and voila more airflow through not only the intercooler but the rad and engine bay.

It would make my car unique and I could always put in some screen or what ever behind the hole to protect from bugs and road debris etc..

What do you guys think? This is one over looked area on our cars the Evo guys have on us. More airflow is good.

[MTZL]

You mean something like this??
Dont ghetto rig it.
Keep it clean, make it look factory as possible.
I like what Mike RRE had done to his RA.
http://clubralliart.com/showpost.php?p=4958&postcount=13

I would like something like that done but dont have the tools or experience cutting metal & car bumper. I would hate to fu@k it up & spend more money to fix it. :(:confused:

[MTZL]

I know I can cut the front bumper with dremel kit I got. Im gonna start drawing some templates & photoshop for placement & rough idea.
(This is something I can do on my spare time).

Man I got some cool ideas...... :D

What can I use to cut the front bumper crash beam?? Mike RRE?

[TheBlackBeast]

I'd be curious as to a workflow too. I'd to add more airflow for increased cooling but certainly don't have the cutting tools for metal/plastic I would need.

[pogiboiuno]

Or you can get a Bumper overlay like this one:
http://rexpeed.net/new2007/product_detail.php?serial=159

AND then cut the holes on the beam. just an idea.

[MikeW-RRE]

The X bumper center piece does not quite fit on a RalliArt. Almost, but needs custom bodywork. On an X, that piece is separate. On a RalliArt, the black is actually part of the bumper cover. Trying to use the X center knocks over a bunch of dominoes. Grille is all different too.

Mike W

[MTZL]

The X bumper center piece does not quite fit on a RalliArt. Almost, but needs custom bodywork. On an X, that piece is separate. On a RalliArt, the black is actually part of the bumper cover. Trying to use the X center knocks over a bunch of dominoes. Grille is all different too.

Mike W

Pic of the Saw to cut the Crash Beam?

[Jackal]

Thanks for the info guys! Post any Ideas here along with any pics.

I think I will remove the bumper cover and make out of the brace by marking out aprox where my openings in the bumper cover will be then simply using a drill, drill a hole in each corner to be able to start a jig saw or recipricating saw or maybe just use a dremel tool. The plastic can be cut with just about anything. I am thinking drill holes on corners again and using sheet metal snips and finish it off with the dremel tool again

[MikeW-RRE]

Pic of the Saw to cut the Crash Beam?

No problem. But dunno if Harbor Freight keeps them in stock at the stores. You might have to order it online.


http://www.roadraceengineering.com/ralliart/silly-stuff/giantsawthing.jpg


Mike W

[MTZL]

No problem. But dunno if Harbor Freight keeps them in stock at the stores. You might have to order it online.


http://www.roadraceengineering.com/ralliart/silly-stuff/giantsawthing.jpg


Mike W

I was thinking I go rent one I dont usually cut anything metal on a daily base to own one.
Maybe I can borrow your Giant Saw thingy there! I can just Saw my RA in halves. oh yeah! I can make it convertible!:p

[wutangmo15]

Haha. Rent it, I'll split the costs with you. Any other Ralliart owners in the Bay Area want to make a convertible?

[GTS_Rob]

omg the size of the blade vs. the size of the people...!!!!

[MTZL]

I maybe able to cut the crash beam with a Dremel or Maybe order EVO X Crash Beam?

[MikeW-RRE]

I used a metal hole saw at each end of the rectangle. Then used a metal cutting jig saw to cut the slot between the holes.

The EVO bumper is aluminum with different brackets. it looks expensive.

Mike W

[socalrallired09]

Hey mike what material is the bumper beam? aluminum or mild steel. Im thinking of using a plasma cutter at my work as long as the material isnt too thin.

[TheBlackBeast]

The EVO bumper is aluminum with different brackets. it looks expensive.

Mike Whahahaha!!!!

That's going in my sig line! Quote of the year maybe?

[MikeW-RRE]

It is a relatively thin high strength steel. A plasma cutter would make quick work of it.

Mike W

[MTZL]

I need to learn how to use one of those Plasma Cutter.
Pretty Cool Stuff better than dremel, my dremel will take forever.
Im fast learner. Going through a slow process.
Bumper Cutting Service for 09 Ralliart? lol.

[Jackal]

If anyone makes cut out or what have you post some pics and maybe a step by step on how the process went and if you would do it again the same way if you had the choice.

[CarGuy]

THAT is hilarious!

No problem. But dunno if Harbor Freight keeps them in stock at the stores. You might have to order it online.


http://www.roadraceengineering.com/ralliart/silly-stuff/giantsawthing.jpg


Mike W

[zeRep85]

New idea...instead of cutting holes like the Evo...how bout making slits like the ralliart symbol?

///////// down the center of the bumper...more ralliart-esque...

Whatcha think?!?!?!?!

[geargrinder]

It could look good, but has the potential to look really ghetto. Much like the Honda people who go wild with a hole saw. Post up pics though when you are done.

[MTZL]

New idea...instead of cutting holes like the Evo...how bout making slits like the ralliart symbol?

///////// down the center of the bumper...more ralliart-esque...

Whatcha think?!?!?!?!

Great idea but you'll lose structure integrity on the slices & thickness between slices on plastic & metal.
From driving with the forces of the wind slices will bow inward with hot temp.

If you take this route, you'll need to reinforce your plastic bumper & maybe the crash beam also so they dont warp.

[zeRep85]

Well maybe only cutting the slips on the bumper but having the big holes on the beam..

+1 reinforcing the bumper behind the slits...

I just dont like the idea of trying to mimic the Evo style bumper..we need to stand out on our own!

[MTZL]

Well maybe only cutting the slips on the bumper but having the big holes on the beam..

+1 reinforcing the bumper behind the slits...

I just dont like the idea of trying to mimic the Evo style bumper..we need to stand out on our own!

yOU MEAN LIKE THIS?

[zeRep85]

yOU MEAN LIKE THIS?

Yup!

The blacked out headlights look good too...if only we can do that..

[Jackal]

Anyone not have any new ideas on how we can mod the stock front bumper for more air flow etc.

[Jackal]

Bump for more Ideas on how to mod our front end for more air flow.

[Blaze]

You could plut a small flap on the bottom of the crash beam.
This would create an upwards vortex of air just in front of an aftermarket/larger IC core.

A lot of domestic cars use this for better radiator cooling.

You can get weather stripping on the cheap at home depot along with 4-6 sheet metal screws.

[Jackal]

I had thought of doing something like this but I am afraid with the bad conditions of our roads up here with potholes debris rocks and gravel I would simply be making a convenient path for this debris to get sucked or directed into the IC or radiator. I will be looking at going to an aftermarket Evo front end of some kind as well as changing to Evo X fenders. Lets continue to post ideas.

[wwralliart77]

So the idea is to direct more airflow towards the IC via "cutouts" to prevent heat soak? If that's the case there is always ic water sprayers to aid in cooling. Plus the slits you'd have to cut out would only help cool slightly. Too much of a hassle for slight improvement imo.

[GAbOS]

Tell that to the F1 engineers. :)

Anything in the airflow department is a plus. If it happens after the grill, I don't see the issue.

[wwralliart77]

F1 cars are super aerodynamic and are built for high speed racing, plus they do not have slits anywhere on them for airflow; rather they have ducts which are strategically placed. Besides I wouldn't be comparing a full featured awd turbo car to a F1 racer. I don't really see the benefit on a daily driver. To each his own though.

[GAbOS]

Was not attacking your comment, bust merely wanted everyone to remember that the little things make huge differences.

F1 cars just make the best reference sine those guys spend crazy amounts of dollars coming up with holes, slits, and ducts in the strangest of places.

One team this year even has exhaust exiting at the front of the side-pods this year to aid in air flow under the car. A lot of teams have radically changed their exhaust schemes to help "push" air under the car to the rear diffusers.

I got carried away. :)

Fav F1 techno-babble link..
http://scarbsf1.wordpress.com/page/2/

[wwralliart77]

No worries. I understand the idea of pushing air to cool along with improved aerodynamics. Like you mentioned the idea is to get the air to be pushed through certain areas; under/over/sides in the best possible way to eliminate drag. I just think the idea of having two holes on the front bumper will create drag at higher speeds, but it's not a real issue since most RAs are daily drivers. Just think there are better options for cooling.

[Drew]

So everyone in this thread is aware that the extra airflow problem has officially been solved? :D

[Jackal]

Yes and in spades have been able to track my car for road racing and drag racing both with the car running a little cooler I can get in an extra lap or 2 but it's my trans that is over heating and stopping me now.

[Topdown]

So everyone in this thread is aware that the extra airflow problem has officially been solved? :D

I know this is an older thread, but that looks like a kit that can be purchased/fitted onto our Ralli's... who makes it, where do you get it?

[BravoZero]

It was designed for the Ralliart by a member here named Drew. You can find it at Mach V Motorsports in Sterling, VA. Here's the link:

http://www.machv.com/larafrbubefo.html

[MTZL]

Maybe one of these days I will light it up with LEDs.
Currently, It was color matched on big Xerox Laser Color machine.
I double the ink with box tape front & back with edge border so moisture doesnt get to it. DiNoc vinyl for the whole grill to prevent fade & debris damage.

http://img51.imageshack.us/img51/3725/frontviewd.jpg

http://img11.imageshack.us/img11/517/dscn2115i.jpg

[MTZL]

http://img17.imageshack.us/img17/6750/20110813171204.jpg

http://img94.imageshack.us/img94/7420/20110813172040.jpg

http://img3.imageshack.us/img3/8775/20110813193054.jpg

http://img825.imageshack.us/img825/3732/20110813193215.jpg

[MTZL]

http://img11.imageshack.us/img11/8836/dscn2127l.jpg

Brackets fitted with 3m tape.
http://img14.imageshack.us/img14/6316/dscn2131i.jpg

http://img808.imageshack.us/img808/4863/dscn2141h.jpg

[TrailBrake]

Nicely done :)

[Jackal]

Awesome job as usual.

[TheBlackBeast]

OK, that's just incredible. Great job!