Following on from this thread;
I got all the parts delivered and I booked myself in for a modding session at my mate Matt's place again. So I went with loads of pics from off of here, this diagram;
and these parts;
I'd read up as much as I possibly could about fitting a universal intercooler and I felt quite confident and equipped to do the job. I was doing everything (as always) on a tight budget and rather than forking out for a 'Pace' or VXR pipe I thought I'd create my own to mount the air temp sensor. Having access to pewter casting facilities I set about casting a small rectangular piece of pewter. This was then drilled and tapped;
Next was to try and round off the underside so it'll sit flush on the 2" alloy pipe i was using;
This proved to be actually quite tricky, so with the help from a mate of a mate who turned up, some zip-tie sized grooves were cut into the top of it;
Combined with Araldite metal weld I got a good solid seal for the sensor;
Now we could attack the car! I looked after mounting the IC to the removed bumper bar with some brackets and bolts;
While Matt looked after moving the radiator back, turning the fan 90 degrees and removing the fan guard;
As you can see he made a lovely new bracket out of alloy to remount the fan, so no need for dodgy zip-ties to hold it in place.
The bumper bar went back on (now with the IC attached) and so the pipe work could begin;
All went very well and as I stocked up on Jubilee clips it meant I could double up in places. All was good until we came to mounting the pipe with the sensor. It's extremely tight between the front cross member and battery tray but with a lot of jiggery-pokery it eventually went in. And after a little trimming of the silicone pipes and tightening of clips it was all done!
I knew that fitting the standard Coupe bumper back over the new IC was going to be problematic but I really wanted to keep it looking standard with the slats in place. Fortunately as the rad and fan were moved as far back as possible it meant that trimming was only required to certain points on the inside of the bumper slats and by using a sharp Stanely it didn't take long at all.
Looking from above;
This mod has cost under £200 and with some general mechanical knowledge a friend to help and a lot of reading up on here I think it's a very do-able mod that will provide quite a hike in performance once suitable re-mapping takes place. What I did also do was take some external temp readings combined with some intake temp readings from my 'Scan Gauge 2' both before and after fitting.
The new FMIC clearly makes a big difference to the temp but the best thing, is how quickly the temp drops back down again to just above ambient, where as before the intake temp would remain very high after giving it a blast.
This is how it all looks;
Unfortunately I can't afford a remap quiet yet but I am taking it up the strip again this Sunday, so fingers crossed it'll go quicker than the 15.4 I managed 6 weeks ago?
Thanks for looking, fire away with any comments or questions and I'd like to say a big thank you to Matt for his help with it all (again).