Aluminum Intercooler Plenum

[lsfourwheeler]

Just finished creating my sheet aluminum intercooler plenum. Super simple design and I cut all the metal with a waterjet and riveted together. I'm planning now to paint it in black wrinkle paint then attach it to the car. I measured my dimensions from my EJ207 V8 intercooler. I think this matches the other 2.0L and not the 2.5L intercoolers but honestly I'm not sure. My CAD is uploaded below for anyone that wants to reference it. Note: my holes for the duct couplers were too small and needed to be enlarged about 1/4-1/2 inch in diameter.

GrabCAD Link: https://grabcad.com/library/intercooler-plenum-for-factory-five-818-coupe-subaru-wrx-sti-1 AFQjCNFnj_Pr1M9XYwMqp_5ShA7qTlE-2A
Hose Flange: https://www.go2marine.com/3-twist-on-hose-flange
Using 3" silicone hose couplers and brake rubber duct from Amazon

At the moment, I have only the roof scoop flowing to it. I have the room on the sides to add more ducting if I decide it's necessary. I want to eventually make the roof scoop larger which will increase this airflow. I have not done any of the electric fans that a few others have done. I don't think it's necessary and the factory doesn't have that sort of setup either.

137852137853137854137855

[lsfourwheeler]

Final product:
137930137931137932137933

[Ajzride]

Very nice. Thanks for the files, I will probably attempt them out of sheetmetal so I can weld/grind smooth and then powder coat.

[lsfourwheeler]

Installed in the car- everything looks pretty good to me. Hopefully it works! My intake temps were never high before...but I also haven't done long pulls when it's hot out so we'll see. Track day this weekend and I'll keep an eye on IAT.

138007138008

[mikeb75]

Very nice! I built a similar plenum out of Kydex for my first attempt, but had integrated some pusher fans to blow across the IC, however, I think your aluminum built one came out much better.

I have some limited track session experience using my v2 (non-fan) plenum; but I wasn't really pushing the car very hard; couldn't go full throttle much in the session because it was a follow the leader run with top speeds of about 90/100 on the straight and much slower for the remainder.

[lsfourwheeler]

I have some limited track session experience using my v2 (non-fan) plenum; but I wasn't really pushing the car very hard; couldn't go full throttle much in the session because it was a follow the leader run with top speeds of about 90/100 on the straight and much slower for the remainder.

Are you also just using the roof scoop for the air source?

[mikeb75]

Are you also just using the roof scoop for the air source?

For those session, yes. Currently, all air to the plenum comes from the roof scoop.