Uprated intercooler- Owners, please help

Hi everybody.. I'm trying to get a winch bumper made for my defender, I want it to sit as flush into the car as poss. To this end, I'm heppy to cut the plastic grille, and the metal grille surround to help. I want to winch to sit right back so that it sits touching the chassis crossbar.

I want to fit an uprated intercooler in the next few months, so my question is

How far forward does your intercooler sit? Dos it sit any further forward, than the chassis cross member?



Thanks in advance

full allisport on my 110. tight fit but it just fills the gap between the rad and the grill.

Thanks, if you were to lie underneath the Defender and look up, would the intercooler, stick out further than the Crossmember then?

i hade this winch bumper made for me and i wanted it as high as possible and as far back as possible..

you can see how much room there is behind with the standard intercooler.
the grill had to be cut to fit

I'm after something that looks as close as possible to the standard Defender Bumper. IE the front of the bumper is one straight length of steel. It'll be made out of thicker steel obviously. The Genuine defender ones stick out really far in the middle, where the fairlead is mounted. This is obviously to enable the winch to be fitted without disturbing the grille etc.

I want the winch as far back, to make it less obvious to the casual passer-by. If I put a cover on it, and fit a bumber plate over the top, it shouldnt be too obvious.

I have done somthing similar although highr up and on a tubular bumper. Sticking out was out of the question (pointles doing all this work to have a fooking big overhang to stop you in your tracks) So drilled and tubed the bumper then put a plate on top.

Sounds good, but I'm trying to keep the defender looking as standard as possible.. I want to put the plastic bumper caps back on too FFS!

I got some 8mm mild steel, some 6mm steel angle and some mild steel tube.
I drilled 3 holes in my front cross member. I then drilled 3 holes in my bumper right the way through.

I then welded in the steel tube and ground it off flush in all 6 holes.

Then I bolted the angle iron to the cross member with 3 bolts using 12.9 Bolts. then I bolted the plate to the front bumper through the tubes with more 12.9 bolts.
Then I had to slide another bit of angle under the plate and bolt it to the 8mm steel so that it was touching the angle previously bolted to the cross member making a Z shaped piece. once thie was all mocked up and clamped together I welded the angle to make the Z piece. This means my winch is bolted to the plate which then attaches to the bumper, the front out rigger and the bolts on the bumper all the strain is shared and I only had to cut the plastic trim out a bit. Although fitting a larger intercooler I think for me is out now its too close unless you go for the deeper type and not the type that sits in front of the rad.