And I tought I had it bad in Canada - that sucks. Personally, Id move from there. Dont people over there have anything else to do but make up ridiculous laws?

 

Look at California's ride height laws; those idiots have more laws than they can possibly enforce.

 

I wouldnt live there either. Ride height laws or no ride height laws.

 

I can read, write, articulate myself in an appropriate way.
I will work hard and don't ask for much.
I'm trained to kick butts, can organize and plan ahead. I can work alone or in a team.
I'm able to fix nearly anything, from bikes to missiles, and can drive semis.
Anybody interested in a loyal german?
Just let me know!

You want some more horror from Europe?
You get it:
If your truck is lifted to much, you have to install a guard like your step rails below to prevent pedestrians getting below and under your truck.

 

Got the dimensions on the slots from the Mercedes dealer today.
There are 2 x 5 slots in it with a length of 215mm.
Each slot is 13mm wide. Distance between the slots is also 13mm.
Distance between the two 5 slot pairs is 16mm.

I'm running out tommorrow to buy a bunch of 1mm cutting wheels.
It's prep time...

 

Pick up a whole saw drill bit in the same size as your slots are wide so you can drill a hole on each end to make the corners. It's the only way you will get clean ends.

 

So I used the first good sunny day to look behind the bumper.



What I found wasn't funny at all:
The small oval opening in the middle below the radiator is the original factory opening for the intercooler. What a bad joke...



I pulled the intercooler out to have free access to the front carrier. The construction itself is interesting. It's a doublefolded unit which is vented by the visco fan. In other words- if the fan shroud isn't sealed there is also no air flow through the intercooler...



To demonstrate how small that surface area of the intercooler is I have put the intercooler seal in front of the carrier.
I have to provide more openings to get a bigger airflow.
To avoid weakness of the carrier I will use a hole punch and punch in several openings to
increase the surface area.



I'm sorry for the lack of pictures- I still use a 35mm camera.
to be continued...

 

looking at the first pic I would try to find a different intercooler, one less thick but wider and taller, also the air to watr exchanger is a good option then you could remote mount the unit like on fender well maybe