Full width intercooler

Hi All,

I fitted an airtec intercooler yesterday on my 300tdi defender. It requires the stays supporting the bonnet slam panel to be required.
Plot twist, after hours of faffing around adjusting the bonnet, I realised that when the bonnet is pushed closed it bends the slam panel and also the anti burst latch fouls on the top of the intercooler.

The latch was easy to sort, I just trimmed it down.

The flexing slam panel is harder to sort. As a bit of a temporary bodge I found a shock absorber bush fits perfectly under the panel and gives the right amount of support - how have others solved this problem with a more permanent solution?

I cut the standard cartch in half (using a hacksaw, along the line).






Then I stid them together and held it with tape, screwd it on the bonnet and offered it up to the intercooler to get a clearance.

Here it is with clearance...



Then, once set, I took it off, clamped it to a bench and welded it together.




Refit and check and it's been fine.

I just removed my catch entirely and fitted military style spring locks that go bonnet to wing.

What slam panel do you have fitted, I get no flex in mine when I fitted a full width intercooler. Is the bonnet fully adjusted and the spring easy to move?