Basically
.... what a day.... fantastic. Had so much fun; engineering with powertools (amazing what entertains the mind of a 28 year old.)
heres the blow by blow.
1)Removed the bumper...
Shizzen the coolers TOO big to fit behind the crash bar... thought about resetting the aircon and engine rads further back, but to much hassel. Also though about removing the crash bar alltogether...no..not safe so ....decided ill cut out a section out of the crashbar to allow for room for cooler to sit behind......easy.
2) worked out some plans for the easiest way to get the cooler mounted...10/15mins of ruff drawings. poking,proding pulling yanking to see what would take the weight.
3) trip down to b&q. (in mates 200sx) Buy some nuts,washers, bolts, angle grinder blades, plus flat and L shapped sections to make up mounts/brackets.
4) get back from b&q , stuffed with burrgerking, keen to get back to work.
5) removed centre guide/support for crash bar(crash bar was off car allready)
6) made top mount for cooler first, a simple "L" shaped bar that runs across both top mounts. drilled hoes for bolts etc..
7) cut centre section down from part "5". and hammer so sits flat/flush to "l" shape bar.... , cut bolt holes and kill all drill bits in the process
8) test fit cooler mounted
9) take crash bar, offered up to original mounting position...now way off , and wont fit for love nore money, marked out a section to be cut away to allow enuff room for the cooler and then some..need to allow for gap between airrcon rad and intercooler. at least 5mm to be safe, and between crash bar and intercooler which i have 10mm.
10) cut crash bar up..., light, thin, soft alluminium....angle grinder cuts through like hot knife to butter.
11) trip to halfords, Drill bits all worn out.....
12) bought self tapping screws, 1m of fuel line and new heavy duty drill bits.
13) cut fuel pipe the whole way down length and then cut it in half. so i have 2 x 50cm lengths with slit all the way down one side. this is so i can protect the cooler from the crash bar i just cut up..
14) Test fitted the cooler and crash bar...everthing fits lovely..
15) now 6pm and running out of light....try to test fit bumper...
16) no joy,,,,which i knew would be the case anyway. so with light against me, decide to call it a day...
17) removed new cooler, fitted bumper back , as i need the car tonight...
so the plan for tommorrow is...up at crack of dawn. Sort bottom mount for cooler...cut bumper up, or rather out, to allow for bottom side of new cooler to fit and refit bumper again....then the pipe work will be next weeks...adventure...
couple of picture of howfar i got on the profile..will update again tomorrrow.