Skip to product information
1 of 17

GrimmSpeed

GrimmSpeed Top Mount Intercoolers - Legacy GT & Outback XT 2005-2009

GrimmSpeed Top Mount Intercoolers - Legacy GT & Outback XT 2005-2009

SKU:GRIM-090027

Regular price $1,008.99 USD
Regular price Sale price $1,008.99 USD
Sale Sold out
Shipping calculated at checkout.
Color

You probably already know that you want an intercooler with maximum cooling and minimum restriction, but we think it’s important to understand why. As air is pressurized by your turbo, it heats up because compressed atoms in the air are forced closer together, move faster, and have more energy. That energy manifests itself as heat. Removing heat helps eliminate pre-detonation, allowing for increased output from your system. Your OEM TMIC does just fine at stock boost under normal use, but as soon as you start putting some real heat into it with higher boost or harder use, it heat-soaks beyond recovery.

Quick Specs

  • 17.5in x 8.7in x 3.5in Cross Flow Core - careful balance of high heat transfer and low pressure drop
  • Cast Aluminum End Tanks - machined BPV flange for precision fit and perfect seal
  • 5-Ply Silicone Couplers - custom molded and reinforced for demanding environments
  • Wide-Mouth Splitter - collects air from the entire width of the scoop
  • Vibration Isolation Mounting - protect the intercooler system from fatigue due to vibration
  • Stainless Steel BPV Studs - avoid the risk of damaging fragile aluminum threads
  • Cleaned, Inspected, and Sealed Prior to Shipping - prevent motor damage due to foreign matter

Design

There are two primary considerations in the design of an intercooler: maximum heat transfer and minimum pressure drop. Unfortunately, one causes the other, so finding a perfect balance requires a detailed understanding of the intended application, some serious engineering power and the highest quality manufacturing processes. Fitment and quality are also critically important to ensure that the most safety-critical part of your turbo system is up to the task every time your foot hits the floor. We began by laser scanning an OEM TMIC to plot the mounting points and space claim in CAD with pinpoint accuracy. At the same time, we designed a custom bar and plate core with overall dimensions, fin density and fin types that would provide the insane heat transfer area we require with minimal flow restriction. With core size nailed down, we got to work designing end tanks that offered smooth flow, perfect fitment and even distribution of the hot charge air through the core. Countless revisions were tested in flow simulation before we finally found exactly the characteristics that we wanted. From there, 3D printed prototypes were used to confirm fitment and we began work on manufacturing details in preparation for verification testing and production.

closeup-635.jpg

Construction

Each intercooler uses two unique end tanks. The first accepts the hot charge air from the turbo and feeds it to the intercooler core. The second receives the cooled charge air from the core and delivers it to the throttle body. These end tanks are precision cast and machined right here in Minnesota. The bypass valve flange is milled flat and stainless steel studs are permanently installed to ensure that the aluminum threads don’t become damaged and shorten the life of the intercooler. Following inspection, end tanks are welded to high density bar and plate intercoolers before the entire assembly is pressure tested, cleaned and sealed for shipment. 5-ply silicone couplers hold their shape in extreme conditions and ensure that charge air makes it to and from the intercooler with no trouble. Splitters are laser cut from aluminum sheet and CNC bent before being assembled and powdercoated with a durable texture black finish. Stainless steel hardware secures the splitter to the factory hood scoop.

welding-635.jpg

Performance

We setup testing to simulate a real world scenario that’s typically demanding of an intercooler. The test vehicle is a 2012 WRX with a GrimmSpeed downpipe, boost control solenoid, prototype intake and professional tuning. On a closed course, we accelerated in 3rd gear from 3000rpm to redline repeatedly, with 5-8sec between runs. Temperature was logged via k-type thermocouples between the turbo and the intercooler and between the intercooler and the throttle body on both units. Ambient temperature here in Minnesota for both tests was between 20 and 22 degrees F.

The results above speak for themselves, but here’s a breakdown. The phase differences between the runs are a result of how quickly we could safely get the car back down to speed for another run, but the important thing to notice is the magnitude of the temperature fluctuations. Predictably, both intercoolers were seeing similar Pre-IC temperatures on each run (180-190F peak), but while the GrimmSpeed Uncoated TMIC kept Post-IC temperatures between 30-40F the entire time, the OEM TMIC fluctuated between 35-75F. This is the kind of consistent cooling that you should expect from a high quality TMIC and is a function of the geometry and design of the bar and plate core. Our high density core has a massive heat transfer surface area but maintains a large enough cross-sectional flow area that there’s very little added restriction. 

The charts above represent average pressure drop and temperature drop for each of the three intercoolers that we tested. It's interesting to see that each intercooler has it's stronger and weaker points, which is to be expected. Intercooler design is all about finding the right balance of heat transfer and pressure drop. As you can see here, we've opted for a large heat transfer with a small increase in pressure drop. The stock TMIC creates a smaller pressure drop, but sacrifices greatly in heat transfer. The 'other' TMIC that we tested offered heat transfer between OEM and GS, but had the highest pressure drop of the three.

 

View full details

Collapsible content

What's in the Box

Warranty Information

RalliTEK BRANDED PRODUCTS LIFETIME WARRANTY

RalliTEK branded products are warranted to the original owner against manufacturing defects in materials and workmanship for the lifetime of the product.

If a RalliTEK branded product covered by this warranty fails due to a manufacturing defect we will repair the product, without charge, or replace it at our discretion. This policy covers only original, unaltered, and unmodified materials and workmanship. This warranty does not cover damage caused by incorrect installation, accident, improper care, negligence, normal wear and tear, or the natural breakdown of colors and materials over extended time and use. Damage not covered under warranty may be repaired for a reasonable rate and a fee will be charged for return shipping.

No payment or reimbursement shall be made for installation, removal, transportation, or other charges. The remedies outlined in this instrument are exclusive and the liability of RalliTEK with respect to any sale shall not exceed the price of the product on which the liability is based.

For warranty evaluation, please contact RalliTEK Customer Service at (503) 619.0055 or info@rallitek.com to obtain a return authorization. Once this step has been completed, your product must be returned directly to the RalliTEK Warranty Department, 13339 NE Airport Way, Suite 500, Portland, OR 97230. All shipping to the Warranty Department must be pre-paid and insured. RalliTEK will not be liable for damaged or lost inbound packages.

      NOTE: This warranty is only available within the United States or Canada

  • This warranty gives you specific legal rights; you may have other rights, which vary from state to state.
  • This warranty does not cover products sold by RalliTEK that are not RalliTEK branded products.

The RalliTEK website sells discontinued, special markup, and slightly blemished products at significant discounts as 'factory seconds' products. This warranty does not automatically cover products purchased as factory seconds. RalliTEK reserves the right to determine if any warranty applies on a case-by-case basis for factory second parts. If approved, the RalliTEK Warranty Department may repair factory second products for a reasonable charge and applicable shipping charges.

MANUFACTURER WARRANTIES (FOR NON-RALLITEK BRANDED PRODUCTS)

Non-RalliTEK branded products do not have any written or implied warranties. Products on RalliTEK.com are sold with the warranty applied directly from the manufacturer. The customer must contact the product brand manufacturer for any warranty details. All products sold by RalliTEK are intended for off-road and/or race use only, as suggested by the manufacturer, and should be installed and set up by professional service centers only. RalliTEK is not responsible for any product failure or failure due to installation. Should a warranty claim arise, the customer and the manufacturer will handle all warranty issues directly.

There is no warranty on high-performance or race-related parts due to the nature of usage.

No payment or reimbursement shall be made for installation, removal, transportation, or other charges. The remedies outlined in this instrument are exclusive and the liability of RalliTEK with respect to any sale shall not exceed the price of the product on which the liability is based.

EXCEPT AS STATED OTHERWISE IN THIS WARRANTY, RalliTEK MAKES NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. RalliTEK shall not, in any case, be liable for special, incidental, consequential, indirect, or other similar damages arising from any breach of these warranties even if RalliTEK or its agent has been advised of the possibility of such damages. Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you. This warranty is governed by the laws of the State of Oregon.

Installation Instructions

Applications

Subaru Legacy 2.5 GT - 2005
Subaru Legacy 2.5 GT Limited - 2005
Subaru Legacy 2.5 GT - 2006
Subaru Legacy 2.5 GT Limited - 2006
Subaru Legacy 2.5 GT Spec. B - 2006
Subaru Legacy 2.5 GT Limited - 2007
Subaru Legacy 2.5 GT spec.B - 2007
Subaru Legacy 2.5 GT Limited - 2008
Subaru Legacy 2.5 GT spec.B - 2008
Subaru Legacy 2.5 GT Limited - 2009
Subaru Legacy 2.5 GT spec.B - 2009
Subaru Outback 2.5 XT - 2005
Subaru Outback 2.5 XT Limited - 2005
Subaru Outback 2.5 XT - 2006
Subaru Outback 2.5 XT Limited - 2006
Subaru Outback 2.5 XT Limited - 2007
Subaru Outback 2.5 XT Limited - 2008
Subaru Outback 2.5 XT Limited - 2009