Delboy2

The kit supplied was as follows :-

An Unpolished Intercooler


Pipework, Clamps, Silicon Hoses,Lower mounting brackets and bolts


Removing the bumper assembly proved quite time consuming as one of the four retainer captive nuts sheared requiring the use of an Angle Grinder

The intercooler was then fitted as per instruction to the Main bumper cross member.



The 2 lower mounting brackets then fit to the Intercooler and locate perfectly with 2 captive nuts on the underside of the car.


The metal work highlighted requires removal for pipe clearance


The drivers side inner wing requires a quite substantial hole so to manipulate pipework into the engine bay.



This shows the pipework from intercooler to throttle body




The pipework from turbo outlet had to be modified due to clearance issues with the throttle body, have a feeling this may not be such a problem with phase 2 manifolds though.


This shows all the pipework in place.


I will post some more pictures of the car with the bumper fitted


Cheers

[Edited by Delboy2 - 1/25/2004 9:54:43 PM]

BoxerFlat4

Del -

Good work there, question ...

What was the modification that you had to do, it's not clear to me from the piccies what you've done.

Delboy2

Fitting the turbo outlet pipework caused a couple of problems, the first being the silicon pipe supplied had an ID of ~50mm whereas the turbo OD was ~48mm. The second being the pipework had clearance problems with the throttle body.



1 - The outlet pipe was cut approx at E & F.
2 - The section marked B was disgarded.
3 - C was then connected to A using the silicon pipe D (~50mm ID)
4 - C was then connected to the turbo outlet using a ~48mm adapted 90DEG silicon elbow.

This removed the problem resulting in :-



Cheers

Delboy2

I have taken a few more piccies today.

The one below shows in more detail the lower mounting brackets.


As shown I have managed to retain the foglights and induction kit with some work. The metal back plated has had about ~10mm removed.


The finished article, the bumper required some severe cutting to enable fitment



Cheers


[Edited by Delboy2 - 1/26/2004 3:49:03 PM]

Benno

Hey Dellboy, I know it's early days but how has it affected power, torque, driveability etc.

Benno

double post

[Edited by Benno - 1/26/2004 4:40:43 PM]

new boy

cheers delboy..
this will be most helpfull...

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Delboy2

Benno - The car appears to drive much better with minimal additional turbo lag. Have notice when setting off after sitting in traffic there isn't the 'flatness' which was fairly common with the TMIC due to heat-soaking. The car does feel more powerful and much stronger through the Rev range but I will be remapping it very shortly after a few other mods have been fitted.


Cheers

harvey

iTrader: (48)

Del Boy My Man. Congratulations and the pics will be a big help to those following you. I am sure that you will agree that for the price the extra effort is well worthwhile.

I also have my intercooler fully fitted and the PIAAs are retained but there was some cutting to do, removing some of the backing plate.
As I am going to replace the TD04 I do not have the car running yet and may have a couple of novel things to try.

Pictures will follow.

Delboy2

I am very pleased with the outcome, the fitting does require a lot of effort but the rewards make it well worthwhile


Cheers

AndrewC

Harvey/Derrick

Do either of you have any photo's of the cut bumper shell?

How difficult is it to work out where the bumper needs cutting?

Andrew...

[Edited by AndrewC - 1/27/2004 11:23:51 AM]

Floyd

iTrader: (9)

Nice pics Delboy, you've made it look easy.

Will you be putting some protective mesh over the i/c now?

F

Delboy2

AndrewC - Before attempting to cut the bumper I made a cardboard template of the Intercooler which I then placed in the bumper so to gain a rough idea of how much material was to be removed. Once the first cuts were made I then tried the bumper on the car which then highlighted any areas which needed fine adjustments as far as material being removed.


Cheers

Delboy2

Floyd - I do have some stainless steel meshing which will be fitted shortly Therefore I may remove the bumper again to add this so enabling me to take some piccies of it to show the amount of material I removed.

ticky

Delboy,
What did you use to cut the inner wing hole larger?
Where are you going to get the mesh from & how do you attach it securely to the bumper.

jameswrx

iTrader: (4)

Nice one

Looks good

Delboy2

Cheers James The inner wing was cut using a very good pair of tin snips as I didn't want metal swarf in the engine bay, as far as the stainless meshing is concerned I already have this in my possession and am currently deciding how to fit it.


Cheers

[Edited by Delboy2 - 1/28/2004 12:00:48 PM]

AndrewC

Started my installation this evening. Slightly different to Delboy's and Harvey's as my car is a MY98.

Pipe through inner wing on drivers side, will pass through existing front hole, but needs wing to be loosened to manoeuvre pipe:


Next 2 pics show amount of trimming needed near FMIC outlet (before) and inlet (after):




I haven't seen it mentioned elsewhere that you have to cut off the number plate bracket from the bumper support panel:


As Delboy says above, lower brackets do line up with captive bolts but brackets need bending:


The compressor outlet pipe safely passes underneath the throttle body, but catches on the heater supply pipe:


More photo's when I finish the pipework and start cutting the bumper.

Andrew...


[Edited by AndrewC - 1/28/2004 10:55:02 PM]

[Edited by AndrewC - 1/28/2004 11:02:53 PM]

[Edited by AndrewC - 1/28/2004 11:24:48 PM]

jim litten

Take it you won't be needing a hand then!


Jim


Off to see if welder has done pipe.

AndrewC

I happened to have a couple of hours free late yesterday afternoon so though I'd better get on with it. You're welcome to come and see the progress anytime!

Andrew...

fuz

AndrewC

Seems to have gone quiet, so I though I'd post a few piccies of my finished MY98 install:

Engine bay:


K&N 57i:


Inlet pipe, not as close to the battery terminal as it looks:


But pretty tight fit between cambelt covers and rad fan shroud:


Final result is worth the effort - even kept the PIAAs:


Andrew...

Jolly Green Monster

iTrader: (4)

looking very nice Andrew!

Been able to dial in any extra advance??

Simon

Franko

Looking great Andrew

I got mine finished yesterday... just a note on the battery terminals... I couldn't close the bonet and was pushing on the FMIC pipe and it touched the live terminal cutting through the plastic cover (same as the one in the pic above). Thank god it only sparked and didnt burn anything out... anyway this got me very woried(Paranoid) so i checked the battery on my mates P1 which is much smaller in height than the one i had so we swaped batteries. The live terminal now sits about 3inch away from the pipe

Anyone who has the live terminal too close... it may be worthwile swapping the battery for a smaller one

AndrewC

I checked the pipe to battery clearance with the bonnet closed and the nearside headlight removed, the pipe didn't move when I closed the bonnet and remained about 1/2" away. I might see if I can move the FMIC exit pipe closer to the center of the car when I remove the bumper to paint the FMIC, another 1/2 - 1" would be comforting.

Simon, I can't fully explore the new power potential due to my clutch, but am using 2-3 degrees more advance in the top row at the same 1.4bar, car was overboosting at first as the FMIC is so much freer flowing than the MY00 TMIC I had previously.

Andrew...

Franko

Has anyone meshed the front bumper to protect the FMIC? I was going to then was advised not to by mates... thought i'd see how it resists stone chips and after 2 days of driving i've already got a few bent fins...

To mesh or not to mesh?

Jolly Green Monster

iTrader: (4)

Andrew,

Many thanks for the info..

Franko,

Although not a Hybrid etc.. but I wondered the same and then after a few weeks noticed some bent fins..

I have now messed mine.. I had the advantage that mine sits behind the bumper further so I bought some mess like chicken wire and doubled it up to give 4-5mm square holes and cable tied it to the inside of the bumper and grill.. cost me £3.99

But I think with the Hybrid sitting so out front you would need to get something a little better looking than chicken wire.. lol

JGM

Franko

JGM,

True it sits so out front hence making it prone to stone chipings, and your right about needing something better than chicken wire... its why mates advised not to mesh as it may not look so good... i'm going to leave it for a few more weeks and then see how it is... Thanks for the advice mate

Jolly Green Monster

iTrader: (4)

Something better looks wise and strength wise I guess..

At least it doesn't effect air flow very much though..

JGM

new boy

hello..just got mine...

how do i take the bumper off please anyone?
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