Intercooler relocation of the 3 core Intercooler from ATI on a 94 Z/28
Updated 7/21/03 Click on the intercooler for pictures of the revisedintercooler postion
Click on the picture to see how the angled intercooler fits in the nose
Click on the pictures to the right to see how I angled the intercooler to mirror the angle of the radiator to increase airflow to the radiator and intercooler.
Click to see comparison pictures of the intercooler angled to mirror the radiator vs straight up
The above picture has the whole foglight eare hogged out and a Stull grille in it's place.  I also relocated the licence plate.
First step in relocating the intercooler is to disconnect the negative terminal of the battery.  Next get the car in the air and remove the front wheels.  Remove the stock air dam and splash guards.  Remove the intercooler and safely put to the side, after that you should be able to get at the intercooler brackets and tubing and remove all of that.  Then remove the inner wheelwells, there are 3 screws and four 7 mm bolts holding the splash guard in place ( see picture 1), while you're under the car, remove the 3 push clips that hold the bottom of the bumper cover to the nose (I'm sure you've all seen these bad boys if you've ever replaced a fog light) next remove the 7 pushclips in (picture 2), next there are two 7 mm screws to remove (picture 3, one screw on each side near the headlights / quarter panel).  Next are two 10 mm nuts and one 10 mm bolt (picture 4) to remove (both sides), which hold the side of the nose to the front fenders.  Somewhere along the line you will need to remove the fog lights and disconnect the turn signal lights.  After all of that you should be able to pull of the front bumper cover.
Picture 1 Picture 2 Picture 3
Picture 4 Picture 5
Now the fun begins.  Remove the factory crash protection (picture 5), there are three 13 mm bolts w/ nuts on each side, once that is removed you can loosly bolt the driver side of the intercooler to the frame rail and on the passenger side I used a plastic wire tie to see how it would mount up, once at this point you can see where you need to drill (you need to drill about a half inch to the left of the stock hole that holds the stock crash protection).  Now you need to do a parts run, I used some 3" mandrel bent exhaust pipe from Dynomax, you will need a 180 degree bend 3" pipe (part # 42323) and a 90 degree bend 3" pipe (par # 320286).  Loosen the hose clamp on the pressureized side of the 90 degree hose and turn it towards the nose of the car.  Now you can figure out your angles of the tubing (see picture 6,7 &8).  After you've determined the angle needed for the main pressureized tube (bigger tube in picture 6) and cut off the remaing portion of the 180 piping, you will need to cut about a 3 inch piece of straight pipe to get the total length needed,  I then had to cut a small piece out of the remaining angled tubing to get the necessary angle to be able to connect to the intercooler.  You can cut up the remaining ATI tubing to supply the necessary tubing.  You will need to pick up about a foot of Gates hose ( # 24248 Green stripe coolant hose) to connect this all together.  I recommend double clamping all of you connections together on each side (have the clamps go in oposite directions so you get maximum clamping power.  You will need to cut the ATI tube that has the blow off connection as the 90 bend will be needed elsewhere (see picture 8).
Picture 7 Picture 8
Picture 6
On to the intake side, the ATI 90 degree elbow with the blow off connection will not work, Gates does make a hose that will work, but you will need to add a blow of valve conenction (see picture 9).  I extended the new tube down into the elbo to prevent the hose from collapsing as the hose wasn't the most rugged thing I've ever seen.  I then used some of the flex tube supplied by ATI to connect the new tubing to the MAF, I one of the small black connectors and cut the 180 elbow supplied by ATI so I could connect to the MAF.
Picture 9 Picture 10
Cruise bracket
Click above for picture of the additional cooling fans ( Perma Cool Part # 19128)
Click above for the lowered air scoop pictures, added a picture 7/20/00 of the way the nose looks with the s/c installed as detailed by ATI
Here's some crash protection pictures
Click on the nose for pictures of the air openings for the intercooler to breath.  I wll remove the front licence plate at the track, behind the "bowtie" is an opening allowing more air to reach the intercooler