Intercooler Project

[martinjs]

Well here's a bit of an update, had to wait a bit longer than i was expecting for all the pipes etc but its pretty much there, the pipework at the top right of the ic is a bit of a pain, sod all room , anyway shouldnt be a problem
rusty bit of pipe
desperately need a decent inlet manifold
im away for a few days so ive abandoned it for the mo'
will post some more pics when finished

martin

[Mihnea]

This will kick some serious *** Martin, good job!!!

[martinjs]

This will kick some serious *** Martin, good job!!!

yeah....Toms....lol...

[Habib]

Thats looks great

[Mark Halligan]

Thats looks great

Yes it does, nice one Martin

Mark.

[martinjs]

I did put the pressure tester in the l/h side of the ic and plugged the pipe which fixes to the throttle body (72mm + 16mm bungs) then pressurised it. and with 1 clip on all the connections had a job getting it to hold more than 1.8 bar, with them done up stupidly tight will just hold 2 bar, so i'll be using 2 clips on all the connections. worth considering for anyone running big boost.

for the record...for my application anyway....there is no more room behind the RS2 bumper over the stock one. It may be deeper but it curves away earlier and fouls my hoses at each end of the i/c more than the stock bumper, it will fit ok though.

martin

[Beetie]

Jesus, never mind ground clearance from the exhaust, its the clearance from the ic now!
But i'll take my hat off to that one, thats awesome!

[newsh]

yowser yowser yowser!!!

[Stick Insect]

Have you ever thought of taking up plumbing Martin?

David

[timucin]

nice!

[martinjs]

Have you ever thought of taking up plumbing Martin?

David

no..but maybe now i should

martin

[Stick Insect]

no..but maybe now i should

martin

They can earn lots of money, just think of all the toys you could buy for the S2 with the extra wonga!

The bracket looks a lot better painted BTW.

David

[porkkis]

Try to design a X-member that goes right over the snub so it actually goes a bit inside from the ends and upwards a bit. Should give you plenty of room and also can handle the snub stress better.

[Stick Insect]

Hi Porkkis, There was so little room for the intercooler behind the bumper the Snub bracket had to have 30mm taken off it. The snub mount rubber is below the crossmember tube and has lateral location made from 3mm steel sheet. It isn't going anywhere. You could happily stand on the crossmember, It's quite strong! The snub mount is actually well clear of the intercooler. the bottom pulley is nearer the intercooler. It seemed to work well. Maybe Martin could post a top view down the back of the intercooler showing clearances.

The crossmember was made in one afternoon start to finish and the pictures are here http://www.s2forum.com/forum/showthread.php?t=2903.

I'll gladly have a go at another custom crossmember if anyone needs any help. The intercooler was a one off from E-bay so the design would be different.

David

[martinjs]

Top marks to david, it all worked out a treat
It wont sit further back because of the pulley and if its any further forward the bumper wont fit, so the pipe work has to be routed up behind it.
i'll take some pics showing clearences.
Think its a universal i/c, not for a specific car, very similar to the hybrid make but they cost a packet.

martin