Bu&&er, wish I knew something about this sort of thing. This is fascinating mate - good luck, and as said, keep us informed! If it was crash damaged, did you not get a chance to drive it before i.e. do a before/after the front mount comparison?

Mike

 

No I have driven it... put four thousand miles on it.. then I got banned... long story though... so I put it in my garage and I cant really bring myself to sell it.. so Decided to modify it some more.. I have enquired and I can use it on track days.... so be afraid.. I need boost!! and lots of it..

I dont know about these thing either, but the more I read on here and the more I play about the more I learn.. (and I work with computers.. not cars)

David

 

newsflash: Friend gets aluminum plate... and free... "err its for a prototype and we might want some more..."

I think something may be made tonight...

David

[Edited by David_Wallis - 4/24/2002 4:27:01 PM]

 

Tonights Pictures...

Cutting the metal..


More cutting, took a while you know! Im Knackered from all that sawing


Even more...


Ended up making the plate myself... as I got the metal free... I hate four jaw chucks.. took me ages to position that...


Pretty eh?
[img]
http://upload.turbosport.co.uk/gallery3/2002424233624641044.JPG[/img]

What can I say.... It looks like a bit of metal to me.


Looks a bit different now though...


Just waiting for superglue to dry hope it will take 30psi
[img]
http://upload.turbosport.co.uk/gallery3/2002424233625249813.JPG[/img]

I have some more pictures of the intercooler but it had an accident with an angle grinder and a hacksaw.. but Im not posting until its done that way if it doesnt work then youll never see the pictures and Ill replace it!

Working all day and then all night isnt doing me any good and I thought my temper was short before... :0 I need beer... Hopefully getting the plate welded on tomorrow... dont have TIG welder so got to get someone to do it for me... Just need to drop it off..

David

[Edited by David_Wallis - 4/24/2002 11:55:42 PM]

 

David

I'm interested in one of those Intercoolers Don't tell too many people or there will be none left I'll wait to see how you get on, that will let me finish off this water jacket thing I'm doing. Will be interesting to compare the results from the 2 different approaches ! Similar minimal costs
I'm dyno'ing mine on Sunday but the radiator is not going to be here in time DOH ! It's going on anyway and I'll just recirculate water through it from a bucket !

 

I can just see you driving along with a bucket on the roof... infact what about a imersion heater tank on a roof rack... should be cheap.. and you could run 22mm copper pipe and pretend its a roll cage...

Somehow I dont think anybody will want to copy our 'odd' approach to modifying our cars!

Mail me about the intercooler if you want!

David

 

keep it coming Just dont let my dad see or he'll think I'll try it on mine

 

"Had an accident with a hacksaw and an angle grinder???"

David, forget being banned, I think you're certifiable

Will drop u a mail.

Nick.

 

Re copying 'odd' approach............. Not until they see the results m8

 

David,

Just thought I'd post to say that it is people like you that keep me reading this bulletin board. I can't see it not working but then again I'm in no position or authority to say so.

Seen as your local to me I could nip across and view the finished project.

I have always struggled to understand why an intercooler costs circa £1,000 when it effectively is the same construction as a radiator and they don't cost that much.

Damian.

 

LOL @ Nick... You only just realised

Andy.. Dunno about your results, youve got it easy with a WRX i've got a uk car 208bhp standard?? HKS exhaust and air filter....Im making a new downpipe soon... and allready flowing headers.. may consider heat wrapping everything as well.. Youve got a much better base.. I need to find 80 bhp before ill be happy.. not easy.. Ive got some tricks up my sleeve though.. (All Im saying is there is no ecu in the car now).. and Im not spending more than 150 modifying this car if I can help it..

Damian Feel free to have a look at the finished project or whilst it is being done... Or anyone else that wants to look is welcome... im in my garage most nights apart from my drinking nights well actually Im just drinking in the garage whilst doing this.. havent been doing as much as I would like at the moment as I have just been respraying my sisters clio so we can sell it.... I think the main reason that they cost £1000 is for the small space that it has to fit to, so theres a lot of development work... Oh yeah.. and because people will pay that sort of money.. so far my total cost is £31 not bad...

David

 

just been out on a nice long lunch 2.5 hrs been and bought a 2.5" dia x 2.5m length of ally tubing.... only thing is I need to get it bent... nobody yet says they can bend owt that big or that thick... so my friend has gone to blatently walk into machine mart and try out there pipe bender... spent enough money there so hopefully they may sort me out..

Inlet manifold has been dropped of to be welded as well, should have that back tomorrow... a new set of metric taps is also on order so I can tap that when it comes back...

Also fabrication company looked at intercooler and said they could weld it all up no problems... so just need to make the right bits up..

David

 

i like the cheek of the machine mart idea

£31 so far eh...better watch you dont shoot over your allocated budget

anyway, excellent project keep us all posted, something ill be doing this summer when i have some time off.

ian

 

David

Why did you not make a new inlet from alloy tubing ?
I'm sure this would have been quicker and maybe cheaper. Somebody on here must have a picture or diagram of a Group A item.
Anyway best of luck and once again nice to see somebody using an older car and doing the work themselves, and not spending thousands of £.

Mark A

 

Mark,

I think you've forgotten about the throttle body....

The new plate/flange is where the TB bolts onto.

Mark.

 

What a fantastic project!!! I'd never have the guts to try something like that myself, keep up the good work, and keep the piccys and updates coming

 

Are you sure !

 

David

I like your style!

£150 was exactly my budget as well but I'm only looking for 250BHP from a MY00. My plans to get this will be secret until reached, as this looks like a competition now

Good luck.

F

 

sorry no pictures today very ill... hangover!

bought tube for 40 quid radiator brackets are welded in though..

David

 

right hangover is nearly gone... Machine mart cant bend the tube and an exhaust company want £25 to bend it which I think is expensive... any suggestions?

David

 

25 sounds ok as long as it's a mandrel bend

(trying to sound like he knows *something*)

 

thats from alpha tyres in armley... power flow exhaust style... whats a mandrel bend is that where you have the curved piece of metal around it?

Its a big hydraulic pipe bender...

David

 

yeah, a mandrel stops the pipe being bent from rippling and gives you a smooth curve - which is probably what you want given that this will be quite a critical bit of your airflow

More than that and I'm floundering, mate.

 

Just a word of warning.
Aluminium alloy tube can be very difficult to bend successfully,
especially if it is thick walled. Largely depends on the alloy though,do you know what it is?
A good mandrel bending machine should be able to do it providing the mandrel is the right diameter. £25 seems OK for what is about a hours work after setting up.
Keep up the interesting project!

 

erm no... is ally tubing, how many sorts are there??

I would rather have it bent than cutting it and welding it.. Inlet is ready to collect.... except have nobody to collect it from morley for me... doh.

David

 

A lot of ally alloy is v.v brittle......may crystallise and crack rather than bend a long way i.e 90deg.....I presume they have some form of heating pre bend.

Mandrel bending is the best way to bend pipe, it stops it necking and seriously reducing pipe dia.

Just to keep you happy....

Good project keep going!

edited due to carp spolling

[Edited by Dr Hu - 4/26/2002 3:36:36 PM]

 

im going to suggest heating it... got two choices really, it will or it wont..

David

 

Just an observation... Most FMICs that I've seen that use alloy piping for the main airway use welded joints. I'm starting to wonder if there's a reason for that.....

...but I have the mechanical knowledge of a stoat. If there's no diodes in it, then I ain't interested

 

I know what you mean... the only annoying thing is the price of getting people to do the welding... Im seriously considering getting a tig welder... may go have a look tommorrow...

Anyway off down the the coburg pub to get pissed now...

David

 

Coburg - is that the one on the corner by the merrion centre?