C20let intercooler

[nova_pipi]

I'm planing on fitting a frontera intercooler to my c20let nova but is there anyway of fitting this without having to cut and weld the front cross member? I've also noticed that there are two different size intercoolers from fronteras, are both okay with a c20let as I am looking at getting the smaller option with less fins due to tightness, it's going to be a 280bhp mk2 gsi just letting everyone know as I heard these have moor room behind the bumper than a mk1.
Thanks
Phil

[Martin.p]

I put a frontier I/c on my mk2, with standard bumper. I had to cut cross member and the bumper iron. But didn't cut bumper plastic.
Now on the same car I'm fitting a gsi bumper. And I'm going to have to cut cross member back even more to get it behind the gsi bumper. (Because I don't want to cut the bumper out)
think you'll have to cut cross member! Unless you want it sticking right out the front!?

[Benn]

Yes there is more room before a mk2 bumper.
Im sure LeeH didn't cut his cross member, maybe have a read of his project thread.

Why do you wanna cut it tho? Does make life easier.

[Martin.p]

Benn, did you trim anything off your gsi bumper? Or was it all cutting metal back??

[Benn]

All metal, at most i sanded a tiny bit of the lip in the mouth. But nothing was cut.

[nova_pipi]

It's just purely to make life easier, didn't really want to cut the cross member to make a recess, I found a couple of pictures of Lee's but I couldn't tell from the pictures if he'd just cut the most protruding parts or had it welded flat

[nova_pipi]

If I had to re weld it what thickness steel would be best?

[Benn]

1.5mm maybe, as you want to keep the strength in there, but try everything first, you might have room.

I didn't try a Frontera one so unsure how they fit.