DIY FMIC Project....
26 April 2002, 05:13 PM
#61
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A local firm did this FMIC for me at cost (as a development experiment.) No chopping, except to the plastic grill and the moulding at the bottom of the airbox - to accomodate the tubing. Wanted it simple so it was easy to return to standard if required. Performance is not as good as Pace/APS/HKS et al, but cost half as much, and on the road appears to be better than standard.
Included pics as you might want to see how they did the pipes - some silocon & some aluminium, welded for the bends.
Included pics as you might want to see how they did the pipes - some silocon & some aluminium, welded for the bends.
27 April 2002, 12:38 AM
#64
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Location: Leeds - It was 562.4bhp@28psi on Optimax, How much closer to 600 with race fuel and a bigger turbo?
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it is indeed the one at the bottom..... and as I work in that big tall building opposite the halifax... its about as far as we walk!
Nice install... looks like they have done something with the bonnet catch which I considered... I am going to have to move my oil filler cap I think... Also the newer turbos mount differntly to the td05 that I have (I think)
I would suggest moving your reg plate down to the bottom though..
Might go plug camera in and get some pictures..
David
Nice install... looks like they have done something with the bonnet catch which I considered... I am going to have to move my oil filler cap I think... Also the newer turbos mount differntly to the td05 that I have (I think)
I would suggest moving your reg plate down to the bottom though..
Might go plug camera in and get some pictures..
David
27 April 2002, 12:49 AM
#65
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last nights pics (thurs)... didnt do much as I needed the manifold back... went to the pub and got pi55sed, bit like tonight really..
May have some pics tomorrow.. off to buy a new welder tomorrow, unless someone in / near leeds has a Single Phase tig welder they fancy selling / lending to me.. if you do then ring / txt me on 07788 577836... either that or if you have a really fit bird / sister preferably under 22 then pass the number on as well
Anyway...
A bit thick... should take a fair bit of boost!
think its three gauge.. 2.5" best I could manage.. downside is it cost me £40
Lovely paving slabs..
Radiator bracket welded back on lower down and further to the left.. needs bracing yet... no comments on the welding though as its usually a lot neater..
Can just see how low radiator sits now.. will weld something across the front to protect it...
A bit close isnt even the word..
All in... just needs pipework...
New set of metric taps arrived today... as all ours are whitworth or af so can now thread inlet for throttlebody bolts...
edited to change pictures... edited in photoshop and increase the brightness... Some of the pics seem really dark for some reason??
[Edited by David_Wallis - 4/27/2002 12:54:36 AM]
[Edited by David_Wallis - 4/27/2002 1:02:36 AM]
May have some pics tomorrow.. off to buy a new welder tomorrow, unless someone in / near leeds has a Single Phase tig welder they fancy selling / lending to me.. if you do then ring / txt me on 07788 577836... either that or if you have a really fit bird / sister preferably under 22 then pass the number on as well
Anyway...
A bit thick... should take a fair bit of boost!
think its three gauge.. 2.5" best I could manage.. downside is it cost me £40Lovely paving slabs..
Radiator bracket welded back on lower down and further to the left.. needs bracing yet... no comments on the welding though as its usually a lot neater..
Can just see how low radiator sits now.. will weld something across the front to protect it...
A bit close isnt even the word..
All in... just needs pipework...
New set of metric taps arrived today... as all ours are whitworth or af so can now thread inlet for throttlebody bolts...
edited to change pictures... edited in photoshop and increase the brightness... Some of the pics seem really dark for some reason??
[Edited by David_Wallis - 4/27/2002 12:54:36 AM]
[Edited by David_Wallis - 4/27/2002 1:02:36 AM]
27 April 2002, 05:37 PM
#67
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More pictures.. got the inlet back have machined out the hole through into the inlet now.. The red stuff is die for testing for leaks / cracks in the welding.. Cant tap the plate as the throttle body is in the boot of my mates car and he's at work.... oh well early start in the pub...
Have removed the fuel rails ready for modification... (See other thread..) dont worry Ill show pics!
Have increased brightness on these photos as well... let me know if they are better...
Couldnt buy a tig welder as the guy reckons you can only get them in three phase... b0llocks I bet I can get a single phase one.. (thats mondays job at work... but Im not working monday so will have to be tuesday.)
Inlet complete with dye...
Another angle...
You cant tell very well but theres now a hole through there... and its been washed out lots..
Another Angle...
Fuel Pipes.. not going back on... being replaced with less restrictive stainless steel braided 8mm pipes.. will mount directly to fuel rail as well..
[img]
http://upload.turbosport.co.uk/gallery3/2002427172446684821.JPG[/img]
Off to the pub early now...
David
Have removed the fuel rails ready for modification... (See other thread..) dont worry Ill show pics!
Have increased brightness on these photos as well... let me know if they are better...
Couldnt buy a tig welder as the guy reckons you can only get them in three phase... b0llocks I bet I can get a single phase one.. (thats mondays job at work... but Im not working monday so will have to be tuesday.)
Inlet complete with dye...
Another angle...
You cant tell very well but theres now a hole through there... and its been washed out lots..
Another Angle...
Fuel Pipes.. not going back on... being replaced with less restrictive stainless steel braided 8mm pipes.. will mount directly to fuel rail as well..
[img]
http://upload.turbosport.co.uk/gallery3/2002427172446684821.JPG[/img]
Off to the pub early now...
David
28 April 2002, 01:46 AM
#68
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pub was crap... no sign of throttle body... got the gasket though.. doh.
David
David
28 April 2002, 02:00 PM
#69
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Re mine shown above - no noticible turbo lag, pipes are not huge which probabily helps.
David, yes they had to fashion a bracket on the intercooler for the bonnet catch, which was sitting where the intercooler went. This took filpping ages to get right, so be warned!!!
Had thought about moving the numberplate, but diddn't as on the WRX there is a blooming great metal beam running L-R across the front. This is masked by a black plastic bit - you can just see it half way down the plate. Thus moving the plate would have made no difference.
Glad to see you are making good progress - good luck.
David, yes they had to fashion a bracket on the intercooler for the bonnet catch, which was sitting where the intercooler went. This took filpping ages to get right, so be warned!!!
Had thought about moving the numberplate, but diddn't as on the WRX there is a blooming great metal beam running L-R across the front. This is masked by a black plastic bit - you can just see it half way down the plate. Thus moving the plate would have made no difference.
Glad to see you are making good progress - good luck.
28 April 2002, 05:35 PM
#70
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ARGH... dont try buying a TIG welder.. there is no usefull info on the net... best looking one I have found so far is a sip one at about 600... None of them tell you how thick they will weld..
At this rate I can feel someone being paid to do my welding... not good.
David
At this rate I can feel someone being paid to do my welding... not good.
David
28 April 2002, 06:55 PM
#71
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David
If you are buying a TIG, make sure it has an AC facility for welding aluminium. Some of the smaller units are only DC.
There is probably a more technical reason but having tried AC/DC welding aluminium, the difference is that you can tell when the metal is molten with AC as it vibrates ripples across it. DC doesn't ! Molten aluminium looks identical to solid aluminium, so you can't tell when it starts to melt...... start weld - nothing happens then big hole appears
......no much fun !
If you are buying a TIG, make sure it has an AC facility for welding aluminium. Some of the smaller units are only DC.
There is probably a more technical reason but having tried AC/DC welding aluminium, the difference is that you can tell when the metal is molten with AC as it vibrates ripples across it. DC doesn't ! Molten aluminium looks identical to solid aluminium, so you can't tell when it starts to melt...... start weld - nothing happens then big hole appears
......no much fun !
28 April 2002, 08:55 PM
#72
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The sip one looks quite good... gas pre weld control post weld control, ramp up / down... blah blah..
Got day off tomorrow... so might go shopping!
David
Got day off tomorrow... so might go shopping!
David
29 April 2002, 09:55 AM
#73
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hehehe - cheaper to pay someone to weld it for you rather than shell out on a TIG welder surely!!!
Or are you going to start a FMIC business
a £600 TIG welder is quite an investment on a budget of £150
Or are you going to start a FMIC business
a £600 TIG welder is quite an investment on a budget of £150
29 April 2002, 10:26 AM
#74
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Yeah... but Im sure ill think of more excuses for a tig??
Erm...
Oh well well Ill have to make myself a strut brace... oil catch tank... swirl pot... and a stainless steel downpipe..
Its one of those things that would be nice to have... besides I could have done with it to do some welding on my sisters motorbike after she dropped it...
Budget has gone out of the window if I am paying for welding... however If i buy the welder... i dont include it.. as it will be used for other things..
Cost so far:
Intercooler £30
Piece of metal (steel) £1
Aluminium Plates £free
Aluminium tube 2.5" dia x 2.5m £40
Inlet Manifold Welding £30
Still need to enquire about prices for samco tubing or similar...
David
Erm...
Oh well well Ill have to make myself a strut brace... oil catch tank... swirl pot... and a stainless steel downpipe..
Its one of those things that would be nice to have... besides I could have done with it to do some welding on my sisters motorbike after she dropped it...
Budget has gone out of the window if I am paying for welding... however If i buy the welder... i dont include it.. as it will be used for other things..
Cost so far:
Intercooler £30
Piece of metal (steel) £1
Aluminium Plates £free
Aluminium tube 2.5" dia x 2.5m £40
Inlet Manifold Welding £30
Still need to enquire about prices for samco tubing or similar...
David
29 April 2002, 07:19 PM
#76
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Cheers I've got there catalogue all ready as I am after some braided fuel hoses....
David
David
30 April 2002, 01:59 PM
#79
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no... Ive sort of lost my motivation at the moment... Mate hasnt brought throttle body around yet... so cant tap manifold... Just trying to decide whether to spend £1000 on a welder or to pay £145 to hire for a week, or to just get someone to the welding for me... dilema or what? Its one of these things you dont know whether you would get the use from it.... but would come in handy to add to my collection of tools 
Chances are one will turn up in a friends garage or second hand a week later.. Dont know what Im whinging about as I spent 400 on a empty snap-on toolbox...
Hopefully should be getting my new fuel pump and pressure regulator soon thanks to the help and advice of a couple of people on here... you know who you are
Need to find some steel threaded ends to weld to some new plates for the fuel rails.. and then get some stainless steel braided fuel lines made up...
Also going out drinking last night in York (Why york??) and getting to bed at 4.30am and then starting work this morning at 8.00am didnt help.. Doh.
David
[Edited by David_Wallis - 27/05/2002 12:37:09]
Chances are one will turn up in a friends garage or second hand a week later.. Dont know what Im whinging about as I spent 400 on a empty snap-on toolbox...Hopefully should be getting my new fuel pump and pressure regulator soon thanks to the help and advice of a couple of people on here... you know who you are
Need to find some steel threaded ends to weld to some new plates for the fuel rails.. and then get some stainless steel braided fuel lines made up...
Also going out drinking last night in York (Why york??) and getting to bed at 4.30am and then starting work this morning at 8.00am didnt help.. Doh.
David
[Edited by David_Wallis - 27/05/2002 12:37:09]
30 April 2002, 02:01 PM
#80
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Forgot to also say that I have modified the alternator bracket now.. but am not happy with the weld showing on it so will have to look into this!...
Also thinking about spraying the inlet manifold red...
David
Also thinking about spraying the inlet manifold red...
David
30 April 2002, 06:41 PM
#81
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some pics.. just showing inlet on.. not done much apart from alter alternator bracket... picture showing state of garage at the moment...
May add comments later as my tea is ready... perks of living with parents!
Inlet manifold in situ.. I have an awful feeling that they have welded the plate on at the wrong angle... May have to have the face ground a bit..
Modified alternator Bracket.... Hammered bar out and then widened the hole into a slot with a file, moving the bar closer to the edge.. then welded in and filled the hole with the welder.. needs tidying..
View from front.. that hole has moved right by about 7mm.. have used a file to make sure it is flat... alternator fits ok..
Pretty self explanatory..
Our messy garage.. have been told I need to tidy it a bit.. (Bench is a mess..)
[img]
http://upload.turbosport.co.uk/gallery3/2002430183050573951.JPG[/img]
David
[Edited by David_Wallis - 4/30/2002 9:02:54 PM]
May add comments later as my tea is ready... perks of living with parents!
Inlet manifold in situ.. I have an awful feeling that they have welded the plate on at the wrong angle... May have to have the face ground a bit..
Modified alternator Bracket.... Hammered bar out and then widened the hole into a slot with a file, moving the bar closer to the edge.. then welded in and filled the hole with the welder.. needs tidying..
View from front.. that hole has moved right by about 7mm.. have used a file to make sure it is flat... alternator fits ok..
Pretty self explanatory..
Our messy garage.. have been told I need to tidy it a bit.. (Bench is a mess..)
[img]
http://upload.turbosport.co.uk/gallery3/2002430183050573951.JPG[/img]
David
[Edited by David_Wallis - 4/30/2002 9:02:54 PM]
added 25 bhp 
30 April 2002, 09:58 PM
#84
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I am coming straight out of the turbo past washer bottle, battery past the now non existent filler cap... till its modified.. Then into the intercooler.. past the side of the radiator as I have shifted it left..
When looking at the car face on the inlet will come out of the manifold and then bend left across the top of the intercooler and then into the intercooler.. No more than 1.5m of pipe I think..
Doh.. I thought I should get at least 50bhp from the red paint... May even chrome it..
Sad innit?
David
When looking at the car face on the inlet will come out of the manifold and then bend left across the top of the intercooler and then into the intercooler.. No more than 1.5m of pipe I think..
Doh.. I thought I should get at least 50bhp from the red paint... May even chrome it..
Sad innit?
David
01 May 2002, 10:25 AM
#85
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Bloody marvellous, this
I do wonder how much someone would charge you to do this. I think it would be a small fortune. Plus yours will be pretty damn unique.
Does the WRC use the same entry point as standard, because this strikes me as such a great idea!
I do wonder how much someone would charge you to do this. I think it would be a small fortune. Plus yours will be pretty damn unique.
Does the WRC use the same entry point as standard, because this strikes me as such a great idea!
01 May 2002, 11:45 AM
#87
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no the rally car does it this way... prodrive used to do it in a similar way... but now they have fancy tubular aluminium manifolds..
David
David
