this tutorial is on a TurboXS intercooler. the basics can be used on any intercooler. just follow the same steps and take your time.
okay, dont you hate all those nasty little rocks and stuff that get gathered up in your new pretty looking intercooler?? dont you also hate it when the fins get bent and now it looks like !#$#$?? well, i did this on my 98 GST Eclipse with a Greddy type 24 intercooler and worked really well. i also did this to my stock intercooler, radiator, and my wifes radiator in her Lexus IS300. let me tell you, it keeps ALOT of bugs/rocks from plugging up her A/C condenser since she does quite a bit of driving.
since their isnt a "how to" on this, i decided to document on how to protect your intercooler.
okay first off, you will need to remove your intercooler. i wont go into explaining that since there are several other threads on how to remove your front facia, piping, intercooler, etc. i will just jump to the intercooler itself. okay, here we go
for starters, you will need some aluminum screen mesh found at your local hardware store. cost me about $8.00 for the aluminum type. reason i chose aluminum is for the retention of shape, cost, and most importantly its aluminum like your intercooler. the mesh itself looks like it is better at allowing airflow through unlike the plastic/nylon type of mesh.
you will also need a straight edge of some type, a tape measure, a marker, and some ultra black silicone.
once you aquired these items it is time to make some measurements. what i like to do is make the measurements of the intercooler about 1" wider for the sides and 2"taller for the heights. more on that later...
here is what you should have by now:
okay, good. i have a nice square to cut out. you can use scissors if you like(recommended). it wont damage the scissors-it will keep your cut fairly straight and uniform. if you try to use a box cutter, it will only tear up the screen. we dont want that. we want it nice and square. you will see why in the following steps.
okay, now you have it cut out. find something around the house that you can use to fold over the screen mesh with. a yard stick will do. remember i told you that i like to measure about 1" wider?? here is why:
take a measurement of 1/2" and fold over the screen. you can do this by laying the yard stick down and using your hand to just fold the screen upwards at a 90* angle first, then fold it over completely. do the same for the othe side. this will keep the edges of the screen from unraveling.