Toyosport 600, 300, 76mm FMIC fitting guild. Also known as the Wellycooer.

[ReDBull]

I fitted this over the weekend and thought I'd post the fitting guild here. I've copied and pasted it straight from my RR.

 

[ReDBull]

As I've been up since 6:15 with the kids I thought I'd post a few photos. I've been reading about FMIC set ups and have decided to go with the Toyosports type B large IC. Known as the Wellycooer due to it's origins in the custom FMIC thread on ASN. I pored a link to ASN earlier in my RR.*
It's a big core 600/300/76mm here it is sat in front of our dishwasher

*A link to where you can buy it. I paid £96 delivered.*
http://www.toyosports.co.uk/intercooler-70-c.asp

On to the pipe work. I'm using 45 degree 76/63 mm silicone reducers either side from core.*

http://item.mobileweb.ebay.co.uk/viewitem?itemId=290362072607&index=3&nav=SEARCH&nid=02221114485

Then 90 deg 63mm alloy beaded joiners (or I would be if I hadn't been sent stainless ones!!!)

http://item.mobileweb.ebay.co.uk/viewitem?itemId=270865713881&index=0&nav=SEARCH&nid=83301232105

Then 90 deg 63 mm silicone hose which then joins up * * to the plastic map pipe on the passenger side.*

http://item.mobileweb.ebay.co.uk/viewitem?itemId=160786524988&index=15&nav=SEARCH&nid=14320667086

To join up with the top turbo hose from the charge pipe you'll need a 63 mm short alloy joiner.*

http://item.mobileweb.ebay.co.uk/viewitem?itemId=160516793157&index=2&nav=SEARCH&nid=62645597597

That's all the parts you'll need other that jubilee clips. I've avoided the T bar type clips as a few people have recommended not using them. *As there easy to over tighten and cause boost leaks by bending the alloy joiners. *But each to there own. Thanks to Dad I didn't *have to buy jubilee clips.

As I still have the original top turbo hoses. I've divided to replace the one from the charge pipe with a 45 deg 63 mm alloy joiner and a 45 deg 63mm silicone hose

You can buy these also from Mr Silicon.*

The pipe work

The driver side pipe work.*

The passenger side pipe work.*

So that's the pipe work. Next was trimming the body work to get the core to fit as far back as possible....

 

[ReDBull]

Next up was getting the core to fit and making beakers. Thanks to Dad doing this part.*

A before photo

We spent a bit of time looking things over to decide ow to get the core to fit as far back as possible. We winter to do this to reduce the amount that needs to be trimmed from the bumper bar, bumper and hopefully allow re fitting of the fog lights.*

Marked up ready for cutting

After cutting. My Dad used a thin wheel in the grinder.*

The top of the core fitted nice and close the the air con vad. But the bottom could get closer. So a little more trimming was needed.*
All marked up.*

Then painted the bear metal

It fits nice and close now. About as far back as the core could go.*

Next up was making so beakers for the bottom of the core. Dad used 6 mm aluminium bar.*

Then it was the top brackets.*

 

[ReDBull]

So while my Dad was sorting out the brakets and the driver side wheel was off. I re sprayed the driver side Brembo. They where in a mess.*

I went a little OTT with the masking!

After six coats for heat proof red pain I bought from eBay. Unfortunately I forgot to bring the Brembo stickers with me.

At this point the beer had begun to flow and dinner was ready. So I forgot to get photos of the top brackets! But here's a side on photo with out Olivia in the way.

http://s594.photobucket.com/albums/...EA-B12C-79093D4CF4B6-378-000000569092AA64.jpg

Mums just cooked a fry up (with black pudding to!!!!) so we'll be back to work soon. I'll keep you posted on progress.*

 

[ReDBull]

For relocating the horn I used the mounting point for the passenger side, side mount intercooler.*

Brackets for the top of the core.*

Top of the bumper bar marked off

Bottom of the bumper bar

This is how much was removed.*

And fitted.*

This is the brake pain I used. Drys very quickly and is good up to 650 C. Bought from eBay*

The jubilee clips used

As we decided to used the rubber air deflector at the bottom of the IC. Everything is a little hight than on other set ups. This means that I won't be able to mount the oil cooler on top of the crash bar. So its going in place of the drivers side side mount IC. Also it means the 45 deg 76/63 mm reducer goes *partly over the thread for the towing eye. I can get the hook on but I wouldn't want to drive a track day like that so I'll buy and fit a strap.
*I'm very pleased with the set up. Just need to fit the oil cooler and re fit the bumper. I've also painted the passenger side Brembo.*

 

[ReDBull]

The photo of the horn mounting was the wrong one I'm sure you guess that.*
Here it is.*

So it's all fitted and I'm back home. I'll post up the rest of the photos later as photobucket is not playing again. Unfortunately there was zero chance of re fitting the fogs so they've been bined. There was a far bit of bumper trimming needed. Mainly the plastic to channel air to the side mounts. Also the temp sensor had to be moved.*
So initial impresions on the test drive. Even driving in traffic at 30 the throttle respons is much improved. The first time I came to a nation speed limit sign. Again much quicker spool of the turbo. When my Dad asked me what does it feel like I replied that the car feels lighter lol. So yes more torque more power. The delivery is much smoother and it pulls harder high in the rev range.*
Driving home on the motorway crusing at 70 in sixth touch the throttle again it more responsive and pulls harder. Then driving down the A15 over taking slow traffic was it ecelleration is stronger and much smoother. I hope this makes sense as I'm tired and need a shower.*
A big thanks to my Dad. I really enjoyed fitting the FMIC. If you're thinking about fitting one have a good read of all the treads on fitting and go for it. It's one of the best £200 you'll spend.*

 

[ReDBull]

Well that's two new Goodyear Aysemtric 2's order from Etyers. They'll be fitted tomorrow. If you've not tried etyres give them a go you. Order one day they fit at a time and place that suits you the next. Always turn up on time as well!
Ok last few photos.
This is what we had to remove from the inside of the bumper.

I'll get a few shots of the with the bumper on tonight as I forgot yesterday.
I'm really looking forward to getting new Tyres and brakes fitted.

 

[ReDBull]

Time for some photos with the bumper on.

The photos aren't great as it's dull out and there're taken on my iPhone. Evern though I did spray it black it still doesn't stand out to much. It's obvious if you now what a FMIC looks look but doesn't stand out. I forgot to mention that we also needed to trim the fog light grills slightly.
Also the oil cooler fitting is a job for another day as we ran out of time. It's going to be mounted in place of the drivers side SMIC. Looking forward to getting the new Tyres fitted so I can go for a proper drive!
Wow I've got a sticky!!!

 

[ReDBull]

Here is also a fitting guild for the K03 platform engine. Prawn wrote it on a MKIV golf forum.
http://bit.ly/NYQSmM

 

[Seal_LCR]

Just wondering how many jubilees you used and what size?

 

[Seal_LCR]

Also what size is the 45mm silicone hose to charge pipe in length?

 

[Seal_LCR]

Just I case anyone is planning this setup don't go through the eBay links, go directly to www.autosiliconehoses.com

They are cheaper on the site and if you have time order one part at a time and they send you a 15% discount code each time mine is ASHHOSE if you wanna try it on your first order

 

[ReDBull]

Just wondering how many jubilees you used and what size?

You'll need ten to do it the same way I did. I can't remember the size a got as I didn't buy them. You'll need two larger ones from the core. Don't use the crappy T-clamps or you'll leak like a sive.

Also what size is the 45mm silicone hose to charge pipe in length?

I just bought the leg size they come as standard and cut it down. When are you fitting it?

 

[Seal_LCR]

Just read this back! I'm hopefully fitting this Saturday and ronin is helping me.

 

[ReDBull]

You'll enjoy it it's good fun fitting it and you'll love the improvent you get from it.

 

[Seal_LCR]

Can't wait mate! Then it's finding a mapper! Have a few in mind but just unsure of who to go with

 

[Nutta121]

Question?

how did you connect the passenger side pipework up to the inlet is it?

the pipes in the pic dont l;ook long enough after they have curved round to enter the engine bay and it looks like you've got about a foot or so distance to cover?

or am i right in assuming that is why you purchased the 45 degree alloy pipe and silicone? to mate up to said pipework? or is that on the other side pipework?

sorry if im not understanding i just want to make 100% sure i get the correct pipework.

also how did you come across the core top brackets?

 

[Seal_LCR]

The passenger side pipe work connects to standard plastic map pipe. The extra 45 alloy and silicone join to the charge pipe to do away with the oem pipe.

If you want any pics let me know

 

[Nutta121]

The passenger side pipe work connects to standard plastic map pipe. The extra 45 alloy and silicone join to the charge pipe to do away with the oem pipe.

If you want any pics let me know

So if its connecting to the oem pipe then that's why you purchased the little alloy joiner?

Pics would make it crystal clear if you could buddy

 

[Seal_LCR]

So if its connecting to the oem pipe then that's why you purchased the little alloy joiner?

Pics would make it crystal clear if you could buddy

U dont need the joiner if you use the extra 45 alloy and 45 silicone as the joiner was for drivers side to oem hose off charge pipe.