Large IC install/pluming

[K7ERG]

Looking good mate!

Just a pity more of the intercooler isnt showing to aid cooling more, but i like the way it looks stock.

Craig

[s2_bo]

Yes that's true billman, That would solve the oil cooler duct issue. I don't think its worth the hassle though.

Took ithe out for a proper thrashing tonight and the oil didn't get any hotter than normal.
Also, there's plenty of space to the left side to make a different shaped duct for the cooler.




Breakdown of total costs:

IC: from ebay's own Intercooler King.
£120 Inc shipping


Stainless Steel:

1.4 meters of 3mm thick 40mm box section
4 x elbows 3mm thick 60mm OD
2 meters of 3mm thick 60mm OD pipe.
1 sheet of 5mm 20cm x 30cm
Total £50 (i think) inc shipping.



1 x 60mm ID silicone elbow
£12 Inc shipping.

20 x Genuine 55 - 70mm jubilee clips (£59p each - Zinc plated not SS)
Total £12

Tig Welding:
Building Xmember & welding Pipework.
£25


Gran total: £220 ish...

[Billman]

yes that is very nice! Good work. Now in oder to have the oil cooler Duct allmost in place the right inlet of the IC should be welded in another position? What do you think?

[Greg_S]

well done on this one bo. Nice route for the pipework too, keeps aux rad in place too. Maybe I shouldnt have sold my one after all

[Dpicariello]

Looks excellent Bo.

Im amazed everytime that the std bumper fits over all of that. Did you have to cut any of the bumper internally?

It would like to do one about 3/4 of the height of yours to leave a gap between that and the aux rad. Might contact the seller to see if they can make some other custom sizes. Overall a 100% improvement over the standard x-member pipework and joints.

If you can wait a week or so Matt, I'll post some pics of the intercooler that I am about to install.
It's not quite as tall as Bo's (looks quite modest in comparisson) but may not require as much work to install.

Just waiting on a cross member that Bo is sorting for me and then will have to make up a bit of pipework to suit.

Dan

[topsparky]

looks spot on bo

[newsh]

Excellent Bo, that was quite a mission!

[s2_bo]

Cheers Guys,

Yeah quite a noticeable difference in pick up and spooling. Seems to boost a fair bit faster and more steady too..

Before i used to get quite a bit of fluctuation and the boost gauge needle bounced around all over the shot until it hit 1.4bar.

Now it goes up Fast ans smoove "cough cough"

but doest peak quite so high.

I used to get 1.4 - 1.45 bar and now its peaking at about 1.35

I think the IC is to big for the K24 - good thing that i'f got a K26 on the way



--

Yeah i had to trim the inside of the bumper a little bit and took off the two brackets that hold each end of the center grill. (they are not need though - there's two more brackets that hold that grill in place so its fine with out them)

This pic shows a little bit better what was taken off.

Baring in mid that i didn't take any measurements and just sized up the bites that had to be trimmed step by step.



IMG_2637r.JPG

[s2_southwest]

Looks excellent Bo.

Im amazed everytime that the std bumper fits over all of that. Did you have to cut any of the bumper internally?

It would like to do one about 3/4 of the height of yours to leave a gap between that and the aux rad. Might contact the seller to see if they can make some other custom sizes. Overall a 100% improvement over the standard x-member pipework and joints.

[AndersS2]

wow!
Great work Bo.
It looks so big whitout the bumper fitted, and not so big when fitted, but all in all superb!

How is the performance?
Any noticeable, or is that only on hot summerdays that you will be feeling a diffrence?

EDIT: think i'll be going for some sort of the same size, so good to see that people have got that IC size fitted on the oem s2 bumper.

[s2_bo]

Good as new!! - infact better!:mischeif:

IMG_2639.jpg

Xmember diagram will be available soon, a forum member offered to convert the measurements in Cad or Auto cad so a 3D diagram should be available soon.

[4WheelDrifter]

Prima!

[s2_bo]

Had to cut out two of the Grill brackets and a bit of the inside of the bumper at each end of the IC.



IMG_2635S.JPG

[MidnightBlueS2]

Superb job, Herr Yacobs !

[s2_bo]

Plenty of room


IMG_2633s.JPG