Custom FMIC - design considerations

[Myki da Pyki]

this is the intercooler im going for now just need some pipework made up any offers?????
2.5" inlet/outlet

5 bar pressure tested !

Core Length : 23 1/4" 590MM

Core Height: 11" 280MM

Core Thickness: 2 3/4" 75MM

End to End" Length: 34 3/4" 885MM

You'l definatly have to remove aircon if you havent already to fit this. Looks pretty much the same as what im running now which is huge so wouldnt have thought it would be great for the cupra mate even with the big turbo. With those lengths and widths i think you'd be better off with a 60mm thick one if you wanted to go thicker rather than wider ect... A thinner cooler is going to cool better for sure

 

[SEATCOOBER]

what are the dimentions of the laguna one???, i know its about 1/3 of the thinkness, but ive made a paper mock up and it does not seem that much bigger than the laguna one only in thinkness and most of it is in the airflow where as the laguna isnt as it is hidden buy the bumper and if i do get it i will be cutting my bumper not getting rid of aircon, thing is i need to try and if it is **** then ive found out and will keep old ic, any suggestions would be good of other coolers!!!!

is there any calculations that can be done to find the right cooler for youir application???

 

[Myki da Pyki]

what are the dimentions of the laguna one???, i know its about 1/3 of the thinkness, but ive made a paper mock up and it does not seem that much bigger than the laguna one only in thinkness and most of it is in the airflow where as the laguna isnt as it is hidden buy the bumper and if i do get it i will be cutting my bumper not getting rid of aircon, thing is i need to try and if it is **** then ive found out and will keep old ic, any suggestions would be good of other coolers!!!!

is there any calculations that can be done to find the right cooler for youir application???

The central bumper bar would pretty much need to come off completely to allow that cooler behind it, its only the thickness of that cooler thats not good, the rest of it seems fine. Robbie stuck up the dimentions of the pro alloy one on the first page of this thread so theres some good dimentions to work from when looking for one.

Not sure exactly how they work out which works best with each application, but if theres one thing ive leant about coolers is that bigger is not better

 

[SEATCOOBER]

i know that bigger is not always better but it is quite cheap and if its **** then ill just sell it on also if i fit this cooler my pipe work will be all one diamtere and smaller, thing is with coolers is trial and error!!!

 

[Robbie C]

My only reservation on that one is that the core seems mahuusive, by my calculations: 590 x 280 x 75 = 12390000 mm^3

Not too sure on the ProAlloy core capacity though to compare unfortunately.

Bearing in mind that's nearly twice the capacity of Myki's and Dave Smith's old cooler I'd question whether it might be a bit overkill, but not sure what best suits the GT28RS? Different story to a k0x

 

[SEATCOOBER]

well ive had a little search and found the laguna ic is 660x305x33 making it 6642900mm cubed but alot of that cooler is hidden by bumber

found this one today

540x230x65 making it 8073000mm cubed making it a little bit larger than daves when running his ko4 what do people think???

 

[Myki da Pyki]

well ive had a little search and found the laguna ic is 660x305x33 making it 6642900mm cubed but alot of that cooler is hidden by bumber

found this one today

540x230x65 making it 8073000mm cubed making it a little bit larger than daves when running his ko4 what do people think???

Although some of the laguna ones hidden in the bumper it still cools it down, just like a radiator does as thats not completely exposed to the air either so dont see how that makes much diference tbh.

That cooler in the pic could be worth a try if got at the right price

 

[SEATCOOBER]

can get it for 100 quid not to bad i think, may give this a go but can not find anyone willing to do the pipe work?????

 

[Myki da Pyki]

can get it for 100 quid not to bad i think, may give this a go but can not find anyone willing to do the pipe work?????

Give Ryan (mr D) a shout he'l sort you out pipework

 

[SEATCOOBER]

will he be able to do it without me car, i want similar to daves old pipework in 2.5 ss?????

 

[Myki da Pyki]

will he be able to do it without me car, i want similar to daves old pipework in 2.5 ss?????

Oh yeh thats the probelm, he'd need to work it on the car but cant do any harm asking him

 

[cupramillo]

Sorry to thread-jack been looking to get a custom forge unit myself. Will be running a ko3s setup, so been looking at the forge universal ones on their website, which ones of them would be most suitable do you think?

http://www.forgemotorsport.co.uk/content.asp?inc=product&cat=0013&product=FMINT204UNI

 

[gazcuprablk]

i was thinkin of gettin a custom forge 1 to would like it a little wider than the am motorsport 1 i have on there now it needs changin as it was on my old cupra b4 i wrote it off and apart from the dent at the top of it is back on my other cupra( big dent but is not split and holds better than standard intercooler), the am motorsport one comes with these pipes your after similar to the tt charge pipe but they're no longer trading and if my car was not back off the road id take my car to mr d as hes quite local from where i live and he could replicate my pipes if needed

 

[SEATCOOBER]

have you got a picture of them gaz????

 

[gazcuprablk]

im not sure how 2 post pics on here will try and find out and get pics up asap

 

[SEATCOOBER]

use photobucket then just copy and paste!!

 

[Robbie C]

OK so reviving my original post and following on from the points raised in http://seatcupra.net/forums/showthread.php?t=201408&page=5 I've been in discussions with Forge about replicating the AM FMIC, as per the below pics:

I've had to do a little bit of guesswork when it comes to the end tank dimensions and the angles the inlet/outlet pipes enter/exit the cooler but I'm going with the following measurements:

I'm contemplating whether to get RS Fabrications to make me up the custom mandrel bent ali pipework or make up my own as Danny Lad has done in http://seatcupra.net/forums/showthread.php?t=154589&page=29 from an ebay kit for ~£60 but I'm swaying towards RS Fabs as it means they can weld most of these pipes together rather than using lots of silicone joins (yes I am a tart).

Either way, just waiting on Forge to confirm they now have everything they need and it should be good to go

 

[DaNnY_LaD]

Looking Awesome Rob

How muchos?

On my charge pipe side its joined twice and on the tb side is joined 3 time...Its tenically one full pipe as the pipe is pushed end to end and use a coupler to use it air tight...

Has worked awesome on my Gt2x is Goes wayyyyy harder than before..

EDit: lol i thought that was yours why not by the cooler i got for £100 posted and fits perfect and is 80mm taller than the A&M one,10mm Wider with 65mm depth...

 

[SEATCOOBER]

looks good mate when you get pipework done at rs can u save the drawings or tell them thet there will be some interest with this pipework, how much?????

 

[Robbie C]

RS Fabs have unofficially quoted me £400 for the custom pipework but that's yet to be confirmed. After Hooch had some issues with them changing the price after the job was done I'm pushing for a written quotation.

It's a lot more than doing it yourself with the ebay kit and some silicone pipe but I really do like the look of the AM setup where most of the pipes are ali welded so I'm swaying towards that idea and to be perfectly honest I'd rather just drop the car off for a week and let them worry about it rather than have to measure up all the pipework myself and make all the little corrections to get it spot on. Just my view point though - all depends on individual budgets I guess.

Forge have quoted £299 + VAT for the cooler but that's before the SCN 10% discount. I'm essentially looking at a ~£750 setup which works out to roughly the same as the standard Forge and Pro Alloy kits but should flow much better.

Danny the reason I have gone for Forge is just that I know they are proven in this field and can knock together a good quality cooler - not just the fabrication but the actual internals too (appropriate turbulators for maximum efficiency etc). I just want the best setup possible for my Hybrid really and cooling is a major factor in that equation.