boom

hi, just checking if its legal to cut a hole in the strut tower to run a turbo dump pipe through exactly like this.
thanks to proVK for the pic

Attached Images

bln355-hole-01.jpg (242.7 KB, 24 views)

pvk308

depends on the state you live in but in qld they are looking at making it illegal to do these sorts of mods as you are changing the structural integrity of the front of the car by cutting big holes into the front sheet metal. looking at that hole there wouldnt be much support for the tower unless it was full reinforced and braced . dont forget commodores are notorius for pushing the strut towers up and often require beating down by suspension specialists

boom

i cut all the metal behind the front bar on my vk to fit the intercooler.

im in NSW, what should i reinforce the hole with? a few people with the hole cut have told me that its not structural and doesnt flex any more than usual? not sure if thats true, just thought id check.

greenhj

never occurred to ya to ring an engineer? in an age where cutting a hole in a bonnet is frowned upon without some structural additions, how the hell do you expect to cut a strut tower which basically supports the weight of the front end, in order to fit a dump pipe?

pvk308

who ever told you that it is not structural has no idea mate if you look a the inner fenders of a commodore it is all one peice of stamped sheet metal with towers spot welded to the sheet metal (hence why qld dot is looking at making this modification illegal becuase of the change to the structural integrity of the inner gaurd). so if you put a big hole in the metal of course its going to be weakened looking at the hole in that front gaurd that would flex alot especillay with entire weight of the front, strut brakes and wheel being supported there by the strut tower. greenhj makes a fair call an engineer would be a great call. apart from an engine builder an engineer is the modified car owners best friend hence why i am working with one occaisonally. have you got any pic of what you have cut and modified. as for bracing i would need to see what you have done, but in that photo im guessing some steel flat bar welded to the chasis rail up the inside of the tyre well both sides of the hole with the some flat bar joining the two bars on the other edges of the hole so the hole is reinforced on all four edges would be a start

boom

i will try and get a pic of the front. havent cut my strut yet.
thats a good call with the bracing. i'll try and talk to an engineer this week.

boom

this is it. just for anyone who wishes to know, without hacking up the front bumper and making your car look like a - VL calais turbo habib - the biggest intercooler you can fit in the space made available by the cut is 600X300. not sure on width but my intercooler is 75mm, has plenty of space in front, but it just misses the metal on either side of the end tanks

i have some sound bar here. would that work for bracing?

Attached Images

DSC04653.jpg (78.8 KB, 13 views)

pvk308

boom where you have cut the bar should be ok as it is atill attached to the radiator support and chasssis rail. where the openings are i would close the ends up with some steel or tin plate by just welding the steel or tin plate into them so they are blanked off and not open it will stop the front bar from crumpling and will give strength to the area plus you can use it to mount the cooler off or as mounting point for lighter objects. i also would add a peice of flat bar along the opening where the front mount will be positioned at the base much like in the fashion of the locating tabs for the radiator where the two pegs locate that way the cooler is securely located and held in place which will give greater strength to the front especially in the event of a head on does that make sense mate

boom

yeah thanks mate. i plan on doing the flat bar along the opening.
just so you know, the part i cut is definitely not structural, its very thin, so thin i cut it with a hacksaw in one stride. the cooler is going to be hung from the top as well.

cheers for your help. i'll find out more on the strut tower hole issue.