Update with pics
Okay, here are some pics of the shielding I put together for the InterCooler.
Also, as you may have given some thought, the TDI engine in a Vanagon is just "hanging" there in the rear.......... nothing like being up front in a Jetta or Golf. So, I've been really burning my brain on ways to shield the engine from all the road debris but at the same time keep it compact and neat.
Well, obviously, I am running out of time as far as our planned trip to Alaska and return to the TDI Fest by the end of the month. (At this point, I'm not sure about going to Alaska....... time is definitely short now!
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Anyway, at a minimum, I'm adding "side flaps" on each side to provide some protection. My brother provided these flaps which I've customized for my purposes. In some of these pics you will see the flap that's been installed on the left side.
All comments are at the top of the photos.
This pic is for reference....... you are looking to the rear of the left side of the Vanagon......straight behind the left rear wheel. So, you can now better understand the need to protect the InterCooler from flying road debris. Keep those two supports with holes in mind as you look at the rest of the photos.
The following photos show the IC shield. The "stuff" is Bondo just smeared over the undercoating (including a little left over mud...LOL). Hopefully, I can come back to this later and provide permenant sealing (even behind the IC)
In the pic below, you can see to the right is an aftermarket mud flap (too cheap to provide black washers). To the left you should be able to see the "side flap." It extends downward 10 inches to roughly the same level as the bottom of the center mount of the carrier bars. It extends from the front of the carrier bar to almost the rear of the engine bay (about 22 inches). It is secured with 4 bolts on a 1/2 inch lip on the bottom of the chasis........works great! Also, notice the two bolts, they go in the holes of the supports on the IC as seen in the above photo . The shield is also "screwed" to the body panel at the top and covered with Bondo.
This is a similar angle as above but shows the left rear shock. The black mark on the aluminum shield is a reference for my use in pounding the metal to provide fit-ment!
A picture is worth a thousand words (so the saying goes). However, a pic can be deceiving too. Here you are looking from the rear left corner. The shield below the InterCooler really looks better than it appears. Also, you can see the one "bumped up" spot on my Vanagon. A previous owner did that.
Below, in this close-up, you can see the exit side (bottom) of the InterCooler directly above the shield. Also, you can see the charge pipe from the Turbo going into the bottom of the IC................ Also, notice the black rubber "side flap" there in the background.... see next pic.
In the pic below, you are looking up from the other side of the InterCooler.....looking at the side flap. Notice the Turbo pressure pipe going thru the side flap? Also, to the left at the end of the side flap you can see the bottom rear part of the InterCooler. The big black tube is the left carrier bar which holds the engine mounts.
I did not take any pics of the three gauge pod before or after I stripped the paint off. I will install it tomorrow in the rough!