Didnt go out in the end... i just had to settle for the two pints straight after work... anyway after watching some cr@p on telly I went out to the garage for a couple of hours...

Chiseling weld off..


Finished Plate for other side now.. Im Quite proud of how well that fits.. its not like me!!


Botttom of intercooler.. with both blanking plates in...


Bottom of intercooler with, err a strip of metal on the bottom.. (this is what the welds were chiseled off)


Close up, showing what needs welding up..


Cutting a length of tube.. nothing like stating the obvious!


Someone give me some ideas of how to join the right hand side of the tube to the intercooler...


This bit...


David

 

I'd buy a 'tight radius' bend from a pipe supplier.

Did you cut the bottom off the I/C ? was it too tall ?

 

bit of samco?

 

I'm thinking about mitreing it (I CANT SPELL ARGH!) dont want to buy anymore aluminium, its a fcking rip off.

I cut about three or four rows off it to give me room to run the pipe back over the top of it.. It means the pipes can be about 1m shorter..

David

 

Also... Phil in Pickering that emailed me... did you get my reply.. as I got a message back saying it couldnt be delivered try .co.uk instead... so I did..

David

 

I thought about that... I dont want to use the bits that I cut off.. I have tried holding them upto it, but it will look like a patch work quilt.. Think I may try flattening a little length of tube and slot it in and then cut at 45degrees either that or the metal sheeting like you said..

David

 

Keep up the good work, im doing two of the poxy things meself, if i would have known you were doing it i would of sorted you out a plate, i had some cast up.If you fancy making your headache even bigger, you can turn the turbo about 45 degrees reposition the
power steering reservoir, run your charge pipe on the right of
inlet runner and your filter pipe on the left, this is about the
shortest rout possible for min charge pipe lenghts.
Good luck steve.

 

Cool more stuff. Keep up the good work.

Steve

 

This really shouldn't be used for muppet activities, but...

"corner".

 

I thought about doing that myself...

David

 

David you are a star...

will keep watching in anticipation!!!

and a bump for ya!!!

 

Just to keep you all happy I am going to go into the garage in a bit and do some work... dont quite know what... but Im sure ill find something to do! -- Only till eight though as its the weekend and I love drinking!!!

David

 

Excellent News. Keep it coming.

Steve

 

Ive now got an uprated fuel pump and adjustable fuel pressure regulator... Thanks to someone on here who posted it before I had even sent the cheque... trusting or what... Think I owe someone a pint for that one!! Just need to place my order from rally designs for the fuel pipe, samco hoses and other bits..

No pictures from last night... well actually there is but its a piece of paper with some fancy scribblings and lots of circles.. I asked my dad how I should be cutting the pipes (at what angle etc..) we (he) have decided at 22.5 degrees I think.. He did technical drawing and is a qualified engineer...(ill take his word for it..) So I just bent a bit of 2.5mm twin & earth mains wire to show where I wanted the pipe to run, he did the rest... The electric hacksaw is set up to cut the angles now.. just needs doing... except Ive had no time today, as I have been fitting an extractor fan in a friends bathroom.... and then fitted a stainless steel exhaust on a nissan 200sx... complete **** of a job... as two of the bolts snapped in the downpipe bit on the turbo.. I drilled it out to tap it and found there wasnt enough room to swing a cat.. let alone the tap.. so I drilled all the way through and used a nut and bolt... doing the second one I managed to snap the drill bit.. (fu&k me that was hard to drill) except I snapped the drill bit off in the hole... (it jammed) and then it wouldnt come out... Finally managed to chisel it out. 3hr job to fit an exhaust... Its not like I wasnt expecting it though!

David

 

Been and done some work and am I knackered... Im still off to the pub though... getting in at 4 this morning then up at 9 doesnt help either..

Heres the pics..

Cutting tubing at correct angle...


New fuel pump and pressure regulator.


Drawing... to work out angles and lengths..


One piece cut...



Saving money... not buying a Tig Welder.. just going to duct tape them instead..


Roughly where its going... A few things need to move...



David

 

slipped to page 2 so btt.

 

Ditto (well almost)

 

Duct tape. Great stuff, held a fiesta of mine together for years...

 

I know someone that sealed there bath with it...

David

 

David,

I have enjoyed reading your little tutorial v. much. I would just like to say keep up the work, this has been one he!! of a decent thread.

If nothing else it gives a deeper appreciation of just what goes into a project of this caliber. I will be starting it myself this winter on my g/f's MY02 wagon (wether she wants to do it or not). Even if no one who reads this thread plans to do this mod to there own project, it gives a greater understanding of the work that goes into it.

The main reason for this post however is... why the extreme interest in why David received the ban. How does this relate to the project in any way. If he wished to willingly discuss this it would have been in his first post of this thread. If David was nice enough to post ever last detail of this project, have the respect to give him his personal space.

Yes, this is my 1st post and i am aware that my post number is visible. But, i have read enough on here. Please don't let this turn into that other impreza message board *cough* "I" *cough* & *rollseyes*.

Thanks for the good reading David and keep it up.

WBEG


[Edited by WideBodyEG - 8/5/2002 6:23:19 AM]

 

'Oop top

 

Hows it going David?
Done any more of the last few days?

Steve

 

CORNER!

Fuzz,

You don't have to read all 28pages each time you come into the thread mate just start where you left off

I have to say I have learned a huge amount reading this thread...

JGM

[Edited by Jolly Green Monster 2 - 8/6/2002 10:45:41 AM]

 

very entertaining thread, you folks sure seem to drink alot!

 

Drink a lot... hmm started at 3Pm on bank holiday monday.. finished at 2.30am...

Havent really done anymore... only just got in tonight after getting my hair cut... Doubt Ill get much more done now as Im off to greece for a week this wednesday.

Having said that I think I may just get myself out into the garage for an hour or so...

Still working out how to get the welding done, I possibly have use of a tig welder but having only done mig welding before, im a bit reluctant to go and practice with someone elses welder.

Still I will have my throttle body back in a couple of days... Also thinking about incorporating waterspray at the same time..

David

 

see Here for further updates on this. This being the ecu remapping, duuuh.


[Edited by Pavlo - 8/6/2002 1:58:22 PM]

 

see above

[Edited by Pavlo - 8/5/2002 9:58:17 PM]

 

You can weld aluminium with a mig, if it is reasonably powerful. I am pretty crap at it, but im sure if you had enough material to practise on you could get the hang of it. Only real difference is you are supposed to use pure argon gas. ( though i dont think it will reall matter that much. I welded a repair on my alloy wheel and it seems to be fine with argoshield 5. )
The main thing with the mig is that the wire needs to be able to feed in pretty fast, and the alu very clean. The wire itself isnt expensive. If you have a mig, give it a go. The normal mig mask is the same, although the arc can be a little brighter than steel.

 

David, you are a LOON I LOVE IT

Keep up the good work!

 

f**kin MARVELLOUS, excellent job , TOP MAN !!!!!!!!