Intercooler Project

[sorens2]

[martinjs]

Tom, i'll see if i can get some pics to show a bit more detail.
i dont have any measurements but should be able to get you some, we sort of guessed the positioning at first and it fitted first time.

martin

[Stick Insect]

Martin, have you got any dimensions close up pics etc of the crossmember. Im getting a local company to me give a qoute for making up an IC of the same size with the end tanks modded for better hose positioning.

Tom, the end plates were 3mm thick cold drawn steel plate. The tubing was 1" thick wall square tubing. The two angled bits of steel tubing were cut at 45 degrees and IIIRC the height from the top of the plate to the front of the crosmember was 3" ( martin could confirm). The Snub mount was cut back to clear the I/C. It was gas welded using a size 18 tip.

The top of the tube was directly under the bumper. The crossmember is best built on the car and have the IC there I reckon.

I was initially worried about rigidity but after standing on it when it was bolted onto the car it is plenty strong enough!

HTH

David

[audiman]

Cheers David and Martin, also what size pipework have you gone for, the chappy looking at doing mine was a bit concerned about pressure drops from such large pipework and suggested going for no larger than 2.25"??

[Stick Insect]

Cheers David and Martin, also what size pipework have you gone for, the chappy looking at doing mine was a bit concerned about pressure drops from such large pipework and suggested going for no larger than 2.25"??

Marco had a very good technical post recently on a thread started by sweeper about Intercooler size etc. http://www.s2forum.com/forum/showthread.php?t=3853

HTH

David

[martinjs]

Well ive used 63mm dia pipe (2.5"), the stock pressure pipe to throttle body is 60mm anyway (and the pipe in the x-member) so didnt think it would be a problem, it runs ok anyway.
marco said not to go larger than the dia of the throttle body intake.
ive got some pics sorted out i'll resize them and post in a sec.

martin

[audiman]

cheers chap

[martinjs]

Ok, these pics dont really show much dimension wise, but should give you an idea.

the dimension between number 1 (the mounting face for the cross member) and number 2 (mounting point of i/c), mine is in the middle of the 76mm thickness of the i/c....is 110mm

[martinjs]

There is about an inch gap between the pulley and the i/c, doesnt look that much in the pic, you can also see the bar welded to the x-member above the snub mount, i didnt know if there should be something in front of the snub to stop any forward/backward movement

[martinjs]

another

[audiman]

Total cost of all the bits and pieces inc. IC?? Just so i have some figures in mind

[audiman]

Looks like i could keep the AC too!! But the aux rad will have to go in the skip.

[audiman]

http://www.grsmotorsport.co.uk/

[martinjs]

Theres a couple more pics in this thread http://www.s2forum.com/forum/showthread.php?t=2903
you'll have to have a look at billing.
costs:-
i/c...£220
3x silicon elbows and 4x straight sections...£90
2x 90deg bends + 2x 45deg bends (stainless)....£40
t piece for d/valve..£10
x-member.....was made by stick insect in return for making brackets for his brakes
about 4000 jubillee clips

[martinjs]

the only thing i'm concerned about is the entry to my oil cooler is slightly blocked.
if i do another trackday i'll have to keep an eye on the oil temp.