More Eaton/Trilogy Modification.

[RocsMerc]

I'm still collecting the missing parts for my Trilogy kit. I already had to modify the Eaton intake manifold to accept the Trilogy adapter plate here. http://www.mercurymarauder.net/forums/showthread.php?t=65752 Now I'm finding more modifications that need to be done to make Cobra parts work with a Trilogy setup. I noticed this while searching for an intercooler. (Which I haven't purchased yet.)
http://t3.gstatic.com/images?q=tbn:ROGjMe3h-c7y_M:http://img4.imageshack.us/img4/4215/p1010002uxi.jpg&t=1
This is what a unmodified Cobra intercooler looks like. Notice the ten small holes that go around it. On the Eaton setup, these holes are used to bolt it directly to the supercharger and the supercharger bolts to the intake manifold. On the Trilogy kit, their used to bolt the intercooler to the adapter plate and the adapter plate bolts to the supercharger and the intake manifold. The problem are the bolts that hold the supercharger down to the plate.
http://www.mercurymarauder.net/gallery/data/500/medium/PICT3475.JPG
There's six larger bolts that go up from underneath to hold down the supercharger. They go right through the flange around the intercooler which means that I will have to drill six new holes into the intercooler. Drilling the holes in the correct position doesn't bother me because I can just bolt the intercooler and the plate together and use the holes in plate as a guide. What is worrying me is that I don't know how thick that piece is from pictures. I know drilling through mettle with a normal drill is not fun. I'm also concerned that I will be manhandling what is essentially a delicate radiator. Does anyone have any advice on the best way to drill out these holes without breaking anything and without dulling a hundred drill bits in the process? Anyone know how thick the mettle I'll be drilling through is?

This is just a random pic I found in the gallery that I thought seemed relevant. It looks like he made swiss cheese out of it.
http://www.mercurymarauder.net/gallery/data/3/DSC02680.jpg

[ImpalaSlayer]

its all aluminum bro, drill away. your bit will be as sharp as when you started.

[musclemerc]

It's good to think things through buy in this case your making a hybrid S/C kit.

Cut, chop, and modify is the only way to make it all work.

Get a unibit and "drill baby,,, drill"

[DEFYANT]

Fear not.

That is my picture your using and I am the guy who drilled the "new" hole in the intercooler. It was missing the provision for access to intake boost / vacuum. I dont know how thick the metal is, but a standard drill bit did fine.

[blazen71]

If you're using a hand drill, use a size smaller drill bit than the hole you want to finish at. If the hole is still too small, then go through again with the correct size bit. Holes tend to drill a little big when used with a hand drill.

[FordNut]

Or you could get a hand-held punch...

[sailsmen]

Why not just do an Eaton conversion?

[ImpalaSlayer]

Why not just do an Eaton conversion?

not to tell his story but i believe he got a pretty good deal on a t kit with a few missing pieces. so with a little time and creativity he will basically have a t kit for about the price of an eaton swap and with out the hassle of moving stuff around.

[sailsmen]

Perhaps he should ask to borrow an installation manual.

[Bradley G]

I have one you can use if you want.
Perhaps he should ask to borrow an installation manual.

[fastblackmerc]

Perhaps he should ask to borrow an installation manual.


I have one you can use if you want.

Just call and ask Jerry, he'll send you the .pdf.

[DEFYANT]

Just call and ask Jerry, he'll send you the .pdf.

....and will probably send you what you need to finish up the kit and install.

[Spectragod]

....and will probably send you what you need to finish up the kit and install.

Yep, he will. I know, I called and asked when I was looking at buying an incomplete kit, this one IIRC.

He said he would gladly sell anyone the parts needed to complete the kit.

Jerry is an awesome guy, he introduced our MM's to the world of boost, and while I believe I should thank him everytime I get behind the wheel of the MM, I also believe he owes me several sets of rear tires.:D

[RocsMerc]

Thanks everyone. I actually already have a Trilogy manual printed out. That thing has been my bible as I'm collecting parts.


not to tell his story but i believe he got a pretty good deal on a t kit with a few missing pieces. so with a little time and creativity he will basically have a t kit for about the price of an eaton swap and with out the hassle of moving stuff around.
This is exactly right. It was an incomplete Trilogy kit, but it came complete with all the screws, nuts, bolts, and washers already. Even for the parts that were missing. At this point, it's almost complete. All I need now is the intercooler core, gasket for the water intake, electric water pump, tensioner pulley, ribbed idler pulley, and all hoses. So the intercooler is the last big purchase (other than the tune) and the last part I will buy used. I also need the driver side half of the coolant crossover tube from Jerry, but I wanted to see if the one used in the Eaton swaps would work with the Trilogy first. Since I'm piecing this kit together, I thought it would be nice to have something different from the traditional trilogy kit visible under the hood. All the other parts shouldn't give me any trouble buying new when I'm ready to install.


So... I should just use a regular drill and drill bit and it won't give me any problems. I was thinking of wrapping the intercooler in a towel while I drill so I don't damage the radiator fins.

[Spectragod]

So... I should just use a regular drill and drill bit and it won't give me any problems. I was thinking of wrapping the intercooler in a towel while I drill so I don't damage the radiator fins.

Not till the drill chuck catches hold of the towel.

[ImpalaSlayer]

Not till the drill chuck catches hold of the towel.
id clamp it lightly in a vise with 2 blocks of wood. drilling aluminum is nothing like steel. it wont grab and twist your hand un less its very thick and you are using a big ass bit

[tjl006]

If you want Rocco I got an extra crossovertube you can have. It will have to be modified but if you decide you want to go with the eaton crossover tube over triology tube, let me know you can come pick it up.

[CBT]

If you want Rocco I got an extra crossovertube you can have. It will have to be modified but if you decide you want to go with the eaton crossover tube over triology tube, let me know you can come pick it up.

Posts like this make me remember why I like this site and the people here.

"I need (whatever)"
"Come and get it."

:beer:

[tjl006]

I also sold him the kit and didnt realize at the time that some things where more of a pain to make the triology work then the standard eaton. But no matter what route he chose modification is necessary for installing the eaton or triology.