RobDon's Leon -

[Damoegan]

Top work as usuale, Rob

 

[RobDon]

Another new pic of what I've been doing over the winter, lower centre grill and number plate mount are gone and the lower aperture is now opened right up and covered with honeycomb grill I got from Germany. Hopefully all you'll see it just a big intercooler - aggressive looking!

http://i312.photobucket.com/albums/ll330/SonicBlueLeon/grill1.jpg

It has turned out really great, I'm very happy with it.

 

[Damoegan]

Thats very nice mate. Very OEM

 

[Scotty_b]

That grill is the tits, ive wantd to strip the front end out of mine but didnt like the open look. Is there much modification to fit it? Apart from the crash bar.

 

[Prebs]

Today I took my front bumper off so I could fit the 19-row Setrab oil cooler, it's mounted on the nearside front, it will get good airflow through the side grill. While the bumper was off I took the intercooler off and cleaned up everything around the front. Found some rust spots so rubbed them down, treated them and gave the front end a coat of satin black hammerite, same with the crash bar.

http://i312.photobucket.com/albums/ll330/SonicBlueLeon/feb0901.jpg
http://i312.photobucket.com/albums/ll330/SonicBlueLeon/setrab1.jpg

The oil cooler is mounted on rubber bobbins, as per the instructions.

I'll be fitting the Backdraft baffled sump, along with the SEM, and powdercoated intercooler pipes, so more updates soon.

Bodywork parts have been painted so will be picking them up this week and fitting.

Looks ACE rob, did you connect the oil-lines for the cooler from a sandwich plate???

Prebs

 

[RobDon]

Not yet, going to do that when I do the sump. Using a Mocal thermostatic sandwich plate yes, removing the factory water heat-exchanger.

 

[lofer]

Rob that looks awesome!

Where exactly did you source the honeycomb grill from in Germany? Was it expensive, it’s a very close match to the original!

You’ve probably already said but I’ll still ask, what are you going to do with the front number plate?

 

[RobDon]

Regula Tuning on eBay, I would never have done it if I didn't find this honeycomb grill material, as I wanted it to look OEM+. It's one of the few big enough to cover this large aperture too.

http://cgi.ebay.co.uk/High-Quality-...photoQQcmdZViewItemQQ_trksidZp1742.m153.l1262

It's expensive but looks awesome, arrived in 3 days too.

Number plate will be offset, sitting just above the side grill on the drivers side (so oncoming traffic/cops can see it clearly).

 

[Phillc]

Rob,cars looking great the mesh is a nice find think i might get some, are those normal windscreen squirties you have on the bumper or head light ones, i'v been looking to do that but have been looking for the seat ones.

 

[RobDon]

They are Volvo fan-type washers, work very well.

When I removed the Pro Alloy intercooler, I found the top bracket in this state:

http://i312.photobucket.com/albums/ll330/SonicBlueLeon/bracket.jpg

I have asked Pro Alloy for a new bracket as I was disgusted to see this, they haven't bothered getting back to me - so much for high quality and customer service! I'm going to try and de-rust this one and have it powdercoated satin black so it doesn't rust again.

 

[Cupra_R04]

Another new pic of what I've been doing over the winter, lower centre grill and number plate mount are gone and the lower aperture is now opened right up and covered with honeycomb grill I got from Germany. Hopefully all you'll see it just a big intercooler - aggressive looking!

http://i312.photobucket.com/albums/ll330/SonicBlueLeon/grill1.jpg

It has turned out really great, I'm very happy with it.

Hey rob how did you mount the mesh and also removing the license plate holder was it difficult and is the shape of the sides of the opening go all the way around?(any pics). Hope that didnt sound confusing. My grill has been smashed for a year and recon that that is a nice idea. Instead of modifying the crash bar i would just be spraying my intercooler black so u wouldnt see the bar as obviously.

Also i can see why you wouldnt be impressed with the pro alloy bracket. If i had that fitted and noticed that i would be well hacked off.

Thanks in advance Mark

 

[lofer]

Wow! That is a mess! I think I might have to have a look at mine. You should do a number plate mount removal and mesh fitting guide rob!

 

[Willie]

Rob

I know its all back together again now but I remember you saying you 'adjusted' the crash bar, what did you do t it and do you have any pictures?

 

[RobDon]

Pro Alloy are sending me a new powdercoated bracket, which won't rust.

After trying a few different things with the crashbar, steel box section and a different intercooler, I just wasn't happy with how it all panned out and I don't want to run with no crash bar. I test-fitted my front bumper today and the grill looks awesome but behind it not so much.

So after talking to Peter at Forge I have ordered a big race intercooler kit and Forge are going to supply the crash bar with the extra holes in it for max. airflow - as per the pic below:

http://www.forgemotorsport.co.uk/images/products/FMINTCUPR.jpg

Once I've sold the Pro Alloy intercooler, the eBay one and a few other things it won't cost me that much to move to the big Forge.

 

[Feel]

Crash bar would look good with silver powdercoat

 

[RobDon]

Hmmm ... maybe yes!

 

[Willie]

Rob would be very interested in some close up pictures of the crash bar when you get it to see if its just the OEM Forge one that I have with the additional holes cut into it.
Always thought it was a bit of a wasted bit of the intercooler behind the bumer/crash bar

 

[RobDon]

My thoughts too, the crash bar, plastic on the grill and the bumper covered a large portion of the intercooler, so I wanted to open it up to get more air flowing to the intercooler. Once I get the Forge kit I will post up pics of it all. Peter said 14 days but will try and get it to me quicker if poss.

 

[Phillc]

Rob, do you have the part numbers for the Volvo squirties i have tried to get them but there are loads.

 

[Damoegan]

Do you get a Incorrect flow code without the SAI, Rob?

If not, how did you get round it?