Originally Posted by BucketMan
Could you take some pics and give an explanation of what and how you did it? Maybe a write up in a new thread? Id like to see how you did this out of curiosity.
Didn't take any pics and not going to take things apart to do so. But, it's pretty easy. Once you take off enough stuff to get access to the intercooler/IC, you drill a hole in the bottom of one of the side tanks. You get a new petcock from the parts store and buy a nut that the petcock will thread into. You then mix up a batch of two part epoxy (JB Weld) and glue the nut over the hole. I drilled 4 or 5 small holes around the large hole to force the epoxy into for a more secure bond. When it's all set up good and hard, you thread in the petcock and viola you now have a drain for the IC.
The reason you use a nut to thread the petcock into is two fold. First, to thread the tank and just screw it in there isn't a good idea. It's two thin and you wouldn't want a blowout under turbo pressure. Second, if ya did decide to just screw it into the tank, the opening of the petcock would be pretty high above the bottom of the tank and you'd not get enough water out to accomplish your goal. The nut is actually a spacer to lower the opening of the petcock to drain as much water as possible.
Hope this helps.