My IC project

[Pisobiker]

Thats a very good method, David, using wood as a template for a well shaped endtank.
I didn't think of this possibility, but I put some big effort on smoothing out internal surfaces and joints, also trying my best to give the tanks a shape which could more or less equalize flow through core's bars.

As a matter of fact end tanks shape and design is probably the main feature for high efficiency ICs.
I've seen many IC designs, on ebay as well as made by well known brands, neither of the ones particularly actractive to me as for endtanks features.

It is out of doubt that most important thing is to taper endtank from inlet to farest end of it:

[Pisobiker]

But thats not all. Also well radiussed edges ad rounded shapes will give better flow and minimize turbulences wich will actually create restrictions in flow.

OEM ABY-ADU inlet of IC look quite well shaped to me.
Look at this one. This is my favourite:

[Pisobiker]

following is a design I don't like at all:

[Pisobiker]

My one is of course not perfect, but that's the best I could do


Marco

[Doug_RS2]

Top Marks Marco

I am too scared to do that to mine. I think I will be getting rid of the oil ducting and I will live with a funny bend on the exit to get to my front mount inlet manifold.

What doesn't fit with the RS2 front bumper? I have the RS2 bumper so would like to know. I am going to have a big hole behind my number plateadn I will remove it for track days or thrashes up into the hills.

[91_S2]

Marco,

Great documentation as usual. Thanks for sharing the info. Where exactly did you order/buy the core?

[Kroegarn]

Top Marks Marco

What doesn't fit with the RS2 front bumper? I have the RS2 bumper so would like to know. I am going to have a big hole behind my number plateadn I will remove it for track days or thrashes up into the hills.

My IC is 70x27x5 centimeter. Height wise there are not much more to put in. The total space is 33 cm inside the RS2 bumper, so if you can get the crossmember to go infront or behind the bumper that is one way to create some more room. The width I´ve been told that 77-78 is absolutely maximum before you have to cut the bumper open, that includes the tanks.

Marco will probably yell at me after posting this pic on my IC
http://www.garaget.org/archive/476/5...-2140-1129.jpg

Belive I´d experienced some more lag with the new IC, although is was well over six months since I had driven the car before.... And now after 250 km it is broken again, turbo failure?! Another six months???

br

/Mike

[Pisobiker]

Thanks for your comments, guys.

I have two email addresses of the guy I dealt with:

ebay@d2power.com
d2power328@hotmail.com

Item is a bar and plate IC with ~68-70mm ID inlet and outlet, side fed endtanks, not polished. 600x300x76mm core.
Price was 360.00 US$ including shipping to Italy and insurance, and I was told he had a few still on stock.


@ Mike:

couldn't see any picture, but I'm sure your job is good



By the way, I was thinking of buying one of those RS2 replica bumpers from that German Company who is advertising on ebay, but cannot have any answer from them. Already sent a couple of emails in the last week.....
Does anybody know anything about them?

Idea was to modify it, cutting and reshaping front main hole, keeping my actual RS2 bumper original......


Marco

[Kroegarn]

Thanks for your comments, guys.

@ Mike:

couldn't see any picture, but I'm sure your job is good

Well actually it is not that good of a job , but anyway here a link to the car instead. Pic of IC is among them: http://www.garaget.org/show.php?car=523

Did not seem to work with linking only one pic... If I take the path to the pic and paste it in a new browser window it did work. But not when it came into the forum. So if you type to not shortened link in a new window it would probably work... well a lot of hazzle for one pic

/Mike

[Pisobiker]

Mike, your jobs look good: pictures aren't of high quality but I like the EM and downpipe.
IC tanks seem well manufactured, but I'm afraid theyr design isn't 100% optimized for efficiency and equalized flow through the core, even though fact you have inlet and outlet at opposite sides (high inlet, low outlet) should compensate a bit. In practical terms and not for competition use, where even a few hp make the difference, I'm sure it's still working fine.

Only way I can think of right now to check roughly how flow in the IC is behaving, is to place two plugs, one at the top and one at the bottom of endtank (outlet side) and measure pressure at both places simultaneously (using two identical boost gauges with a "one way" valve each, to have the "max boost" reading "recorded") and compare them.
The least difference the best, of course
If you record more than 0.2-0.3 bar difference on peak of 1.7-1.8 bar boost @ the manifold I guess it might be worth manufacturing new endtanks.


A bit "tricky", maybe..... but if you want the maximum out of things sometimes is necessary to go "the tryal and error" route.....




Marco

[Dr H]

Mike

What make of wheels do you have on your car? Are they 18"?

[audiman]

All those coolers are now gone Marco. Doug and myself had the last ones

[A6 AVANT]

Doubt you could ever mod an S2 to it but the latest ford zetecs (fiesta/focus) have the air filter mounted on top of the inlet manifold. i.e the inlet manifold is mounted inside a plastic case that incorporates the air filter box hence the manifols is always cold due to the air flow through the filter! Why has no-one thought of this before! I serviced one a couple of days ago and was very impressed!
Might lead some of you to think about it as space saving in the engine bay is always a priority!
HTH
Chris

[RIX]

Thanks for your comments, guys.

I have two email addresses of the guy I dealt with:

ebay@d2power.com
d2power328@hotmail.com

Item is a bar and plate IC with ~68-70mm ID inlet and outlet, side fed endtanks, not polished. 600x300x76mm core.
Price was 360.00 US$ including shipping to Italy and insurance, and I was told he had a few still on stock.


@ Mike:

couldn't see any picture, but I'm sure your job is good



By the way, I was thinking of buying one of those RS2 replica bumpers from that German Company who is advertising on ebay, but cannot have any answer from them. Already sent a couple of emails in the last week.....
Does anybody know anything about them?

Idea was to modify it, cutting and reshaping front main hole, keeping my actual RS2 bumper original......


Marco

i have bougth one of those bumpers from cmc-automotive they fit okey at least on my s2 avant (triel fittet only waithing for audi to paint it),but you have to make new brakets for the indikeytors but they are not so hard to make,will post pictures when i am finish with my accident repair.

[Pisobiker]

Thanks for feedback RIX,

strange thing is, after my 3th email, they answered telling me they actually don't ship to Italy, for don't know what kind of claimed problem, while shipping only to Germany and Austria.....

Sounds pretty BS to me


Marco


P.S. Does this bumper fit RS2 fog and side indicators without interference?
Is it made out of fiberglass? what average thickness?
I might try again to call them and see. If other people on the forum might be interested we might ask for a "group discount" or at least convince them to ship on other Countryes as well.

i have bougth one of those bumpers from cmc-automotive they fit okey at least on my s2 avant (triel fittet only waithing for audi to paint it),but you have to make new brakets for the indikeytors but they are not so hard to make,will post pictures when i am finish with my accident repair.