Custom FMIC COMPLETE:)

[Black TDI Turbo]

Hey everyone just to let you all know since having my intercooler before xmas i got round to fitting it this weekend. Also fitted a intercooler water spray system and all is well. Took it out for a little drive today after finishing the water spray and all is great, seems to pull much harder all the way up the rev range and might just be me but i think my dv noise got louder, might just be wishful thinkin tho, ill try and post up all of my pics from yesterday and today later on tonight when i get it. Cheers.

 

[high on dirt]

Lets see some pictures i like the idea of the water spray sounds great! Where have you mounted the tank for the water?

Nick

 

[cuprabaz]

probably the washer tank. I used my rear wiper port on the pump for mine and works a treat.

 

[chris999]

what so just spraying water onto the front of the intercooler gives you even more benefits? i learn something new everyday in the world of turbo beasts!

 

[Black TDI Turbo]

Well here you all go, pics of fitting the FMIC and what a job it was took from 8:00am-10pm, partly because im so fussy and everything had to be just right but thats just how i like it.

New Intercooler - http://i40.photobucket.com/albums/e202/C-Taylor/DSC00423.jpg
http://i40.photobucket.com/albums/e202/C-Taylor/DSC00424.jpg

New Vs Old -
http://i40.photobucket.com/albums/e202/C-Taylor/DSC00603.jpg

Before removing bumper -
http://i40.photobucket.com/albums/e202/C-Taylor/DSC00596.jpg

Front bumper and cross member removal -
http://i40.photobucket.com/albums/e202/C-Taylor/DSC00598.jpg
http://i40.photobucket.com/albums/e202/C-Taylor/DSC00599.jpg

Remounted radiator and aircon backwards and secured -
http://i40.photobucket.com/albums/e202/C-Taylor/DSC00608.jpg
http://i40.photobucket.com/albums/e202/C-Taylor/DSC00610.jpg

New cooler on and brackets fixed to bottom of crossmember -
http://i40.photobucket.com/albums/e202/C-Taylor/DSC00611.jpg

New pipes all made by me using 2" piping and 4 intercooler hoses (from a 2.5 BAR rated) FORD focus C-max diesel. (NIGHTMARE OF A JOB) -
http://i40.photobucket.com/albums/e202/C-Taylor/DSC00640.jpg
http://i40.photobucket.com/albums/e202/C-Taylor/DSC00613.jpg
http://i40.photobucket.com/albums/e202/C-Taylor/DSC00612.jpg
http://i40.photobucket.com/albums/e202/C-Taylor/DSC00639.jpg
http://i40.photobucket.com/albums/e202/C-Taylor/DSC00619.jpg
http://i40.photobucket.com/albums/e202/C-Taylor/DSC00616.jpg


Very Late and very tired only need front bumper strip and number plate fitting -
http://i40.photobucket.com/albums/e202/C-Taylor/DSC00628.jpg

Pics this morning and water spray fitted -
http://i40.photobucket.com/albums/e202/C-Taylor/DSC00631.jpg
http://i40.photobucket.com/albums/e202/C-Taylor/DSC00641.jpg
http://i40.photobucket.com/albums/e202/C-Taylor/DSC00642.jpg

Well i know how people like to see lots of pics so feel free, any comments please they are all wlecome Cheers

 

[gazjones]

looks like some good work there! looks good

 

[dj_bigfella]

thats a good DIY job! would love to do that stuff myself but i'm not a hands on person! intercooler looks spot on aswell!

 

[Smoki333]

Looks sweet, bit like my frontera cooler. nice work

 

[Black TDI Turbo]

Took me all day like to get it how i wanted it, am pretty fussy so i wanted it to be rite, and yeh DIY is the rite word to use, took ages to decide where to put the pipes and how to mount the intercooler, fabricated the brackets from sheet metal and had to cut the pipes and join with the metal tubing. Overall i think it looks different and imo pretty damn good, didnt cost alot either.

Intercooler - £130 all in from america
metal pipe - £5.88 for 2" x 2m
hose clips and rubber pipes - all free from work, ex-warranty parts nothing wrong with them but were getting thrown out, plus there rated to above was ill ever go to soo should be ok.
washer pump - free from scrapyard
mondeo rear washer jet - free from work
washer pipe - £1 for 3m from local motor factors
t-piece from halfrauds 54p with tradecard

so overall a cheap alternative to anyothers that have been tried, car feels like it pull alittle better too but need to get vagcom on it to monitor intake temps.

 

[gavthelad]

that definately looks like a pukka job there matey......will be interesting to see what sort of temps your seeing now, if it feels like it pulls better you obviously havnt lost any boost so it appears the cooler is well made.

 

[Black TDI Turbo]

CHecking on the boost gauge nothing has really changed alittle more vag under no load but thats about it seems to pull alot better hgher up the rev range and everything seems well, made a thread about fitting a intake air temp sensor and gauge into the pipework so i can measure the intake temps to switch on the water spray but got mixed comments.

 

[black pearl]

same fmic i have bought

 

[gavthelad]

really good for the price considering many have failed with the custom route!!!!

 

[Black TDI Turbo]

Ive took my time with this so that it was done correctly and checked it all before refitting the bumper so that it worked, im going to try and get someone to vagcom it soon to measure intake temps to see what a difference if any it has made, if i cant find someone i might fit an air temp sensor. Ive got a good place to fit the sensor in one of the pipes also just need the gauge and sensor really but debating on wether or not to do it.

 

[karl.w]

interesting pipe route as i was thinking about routing the pipes that way.

would be good to see what the intake temps come out as...good job

 

[pdcupra]

looks like you've done a neat job there, interested in seeing the logs, hopefully it will be a laguna challenger! - alot of people dont want to do any cutting - seems like the perfect alternative.

 

[cuprabaz]

what so just spraying water onto the front of the intercooler gives you even more benefits? i learn something new everyday in the world of turbo beasts!

Erm no not as simple as that. The water has to be a fine mist so that it evapourates rapidly upon contact with the IC removing heat otherwises it reduces the efficience of the IC. Washer jets don't make water into a fine enough mist for it to work properly. Water injection style nozzles are what you need to do it properly.

 

[chrisbond69]

you can get these nozzles for about £10 from subaru

 

[Black TDI Turbo]

Have you seem one of them work, i serviced a subaru imprezza wrx sti 53 plate last week at work the baby blue coloured ones with black wheels and i checked that spray, was shite compared against the mondeo rear washer, it has a really fine mist better than ibiza front washers. Ill hopefully be able to do some logs soon. It seems a cheaper option however the pipes i used were from a focus c-max and to buy from ford they are quite expensive soo.

 

[Black TDI Turbo]

The more i drive it the better it feels tho pulls stronger.