Got my water line fitting and cut the heater return hose to fit it in. I decided on this because the teflon hose i have wont work with a hose clamp. Came from hong kong fairly quickly and is 26mm. This is for the water return.
The fitting is is a -6 jic to 1/8" NPT. I am using -6 hose for my water lines on the turbo.
Made turbo water feed line. Note heat proof material covering. Need to get it sewn on for added piece of mind.
Had to finish the DP so it could be connected to the cat. I stated off by trying to work out the angle the the pipe needed be so it would connect the the cat. I worked out by doing some measurements, that it was about 20 degrees. I had some PVC pipe and made up the shape using my cone layout program. It fitted right.
I then transferred it to the stainless and marked it out.
Then i cut section out using an angle grinder and inox disc, cleaned up after with a belt sander.
I then tacked it to my Home made cat flange.
After offering it into position, it was lined up and tacked to the rest of the DP.
Then it was welded up to seal it. Here it is complete. Only need to add wastegate outlet pipe to finally finish it when the 1.75" pipe arrives.
To complete the downpipe i had to weld on the wastegate pipe.
I had the flange made at work and got a 1.75" 90 deg bend. It was cut to size and trimmed to fit onto the DP. Although it sounds simple it took ages to get the right shape.[:x]
This is how the pipe would be fitted.
Once the right position was found, the pipe was marked and the hole was cut out.
I then welded the pipe into position. Will be welding flange on tomorrow. I also had to remove studs from wastgate and replace with bolts, because once fitted, the downpipe would be impossible to remove.
Downpipe completed. I'm going to wrap it,
Had to try and fit the intercooler whilst keeping the A/C. Couldn't find much info on this apart from knowing the rad had to be shifted back towards the engine about an 1".
A new rad was sourced and fitted int the front panel after trimming most of the panel away to allow the rad to be moved back.
This was the first option, which mounted the rad on the inside of the original mounts. I found this sat it too far in that i couldn't get bottom hose on right.
I then decided to chop drivers side mounting holes and make some brackets to secure that side of the rad.
Ended up like this. This ali bracket bolted to the rad, pulls it back just enough to allow space for cooler. I have made another bracket to secure the other side but its not fitted yet.
It was then time to feit the I/C in place with rad and A/C heat exchanget in place. I couldn't fit the crossmember on so i cut the whole back of it out and trimmed it until it fitted nice.
Once i had it in place, i realised i had no waw of securing it. I trimmed the back of the crossmember that i'd cut out earlier so it didnt foul the I/C and rewelded it back on. I the set about making some templates out of cardboard to fix the I/C to the crossmember.
I got it all into position and started by fixing the bottom mounts to the front panel.
The bolts needed were M8. I bought them from B*Q but they only did 20mm long. They needed to be around 12mm, so they were cut down. The split nut shown is used so that after the bolt is cut (and deburred), you removed the nut and it leave the thread intact and you can easily fit it into where it meant to go.[
] (Old technique from college).
I then drilled the panel and bolted the middle and N/S bolt to the I/C. The O/S hole hangs off the panel slightly so will sort that another time.
Here's a pic of the I/C i have used. Held in place by the bottom bolts.
I then started making some bracket to fix the top of the I/C. Using some cardbourd as a template, i transfered it to som sheet steel and bent and drilled it to make a bracket.
It was fixed in place to test position.
I cleaned up the back of the crossmember, drilled some holes onto the bracket so it cold be plug welded into position.
I started with the centre and N/S again The 3rd one is part done and will possibly finish that tomorrow and start the boost piping.