front mount intercooler pipe run..??

[raj]

as my build is nearing completion, i have one last job left to do. and that being making a pipe run for the front mount intercooler.

now the turbo to i.c run i can sort myself.

im just stumped on how ill route the carb to i.c run

i have no space to go over the alternator as i have an inline oil stat sitting there.
i cant see the pipe work getting inbetween the chassis and alternator belt either.!

the only idea i have thought of is if i drill a large enough hole just behind the o/s headlight for the pipework to pass through and reach the i.c with a few bends!

any other ideas welcome.

here are some pics of the engine bay -

[Brigsy]

Through the drivers side inner wing might be your only route by the looks of it, no room in the usual spot.

[raj]

Through the drivers side inner wing might be your only route by the looks of it, no room in the usual spot.

are you thinking of a spefic area on the inner wing? as i can only see it being possible at just behind the headlight. i dont want the pipework ending up being rubbed by the wheel.!!

[Ross99]

raj can you do a step by step of this please photo wise, i have the same core and pipe work ready but stuffed, as it just looks to tight everywhere

[raj]

raj can you do a step by step of this please photo wise, i have the same core and pipe work ready but stuffed, as it just looks to tight everywhere

ill do my best, but cant promise when it'll be done. i always take photos while rebuilding anything as a reference , you just have to bare with me

[Kraig]

What radiator is that?

[Brigsy]

are you thinking of a spefic area on the inner wing? as i can only see it being possible at just behind the headlight. i dont want the pipework ending up being rubbed by the wheel.!!

Just behind the headlamp raj, try a dummy run with some foam lagging with a bit of stiff wire, see if it clears the wheel ok. Ive seen a few done the same so must be tight but do-able

[Mudslinger]

re possition the oil cooler and maybe try moving the radiator along abit

infact it looks like the radiator is pretty big , is it really needed ??

[Andrew Cooke]

through the bonnet, across the bonnet, around the outside of the grill, and back through the bumper. Mad Max style, you know you want to

[raj]

Just behind the headlamp raj, try a dummy run with some foam lagging with a bit of stiff wire, see if it clears the wheel ok. Ive seen a few done the same so must be tight but do-able

ok kool,

actually im sure there a guy on here that has his pipe run through the wing?? he crashed his 5 a while back and had grey and orange turbines?? he sent me pics but i lost them alongwith everything else on my knackred laptop

im wanting to use as much hard pipe as possible too.

[raj]

What radiator is that?

its a extra van 1.9 diesel radiator,
a very tight fit even with the 16" slimline fan.

[raj]

re possition the oil cooler and maybe try moving the radiator along abit

infact it looks like the radiator is pretty big , is it really needed ??

cant move the rad in any direction, as for is it really needed? probably not but i just fancied to do something different looks like you know something about doing something different dont you mud

[raj]

through the bonnet, across the bonnet, around the outside of the grill, and back through the bumper. Mad Max style, you know you want to

oh hell yeah. fuk it im doing that

[Mudslinger]

cant move the rad in any direction, as for is it really needed? probably not but i just fancied to do something different looks like you know something about doing something different dont you mud

LoL

yeah but if space is becoming an issue replacing the standard rad could be an easy alternative .

Im still using oe rad but with seperate oil cooler and i find mine still runs a little to cool which is something you dont normally say with a 5 ..

[raj]

LoL

yeah but if space is becoming an issue replacing the standard rad could be an easy alternative .

Im still using oe rad but with seperate oil cooler and i find mine still runs a little to cool which is something you dont normally say with a 5 ..

cant do that mate, it'll cost me more as i dont have a std rad/fan anymore and i dont think the 16"spal fan will fit to the std rad?maybe wrong though.

plus anyway, its defeating the object.! i want this rad anyway its different and i like it.

[Mudslinger]

cant do that mate, it'll cost me more as i dont have a std rad/fan anymore and i dont think the 16"spal fan will fit to the std rad?maybe wrong though.

plus anyway, its defeating the object.! i want this rad anyway its different and i like it.

Looks like ull be running the I/C pipe work the way Mr cooke suggested then

[raj]

i dont think i'll move the oil cooler, but i might look into re-routing the oil cooler pipework to come in from the opposite side of the rad..?

maybe this might give me just enough clearance to run the i.c pipe run over the alternator??

for those that have the i.c pipework running over the alternator...... did you have to fit a shorter belt and a campus crank pulley to get abit more clearance.? or is there just enough space without these.?

i plan on using 2" piping

[Mudslinger]

i use a shorter alti belt to give a tad more space , ive been looking for a pic of where i mounted my oil cooler to show you , but cant find 1 , its basically mounted in the wheel arch behind where the fog light would be ,needs a little work to make a couple of brackets and some sort of protection from stones but it sits in there perfect .

Oh and be carefull how you run any braided hoses as the have a tendacy to eat through anything that it rubs against .

[Mudslinger]

Found a pic

[gttjames]

i use a shorter alti belt to give a tad more space , ive been looking for a pic of where i mounted my oil cooler to show you , but cant find 1 , its basically mounted in the wheel arch behind where the fog light would be ,needs a little work to make a couple of brackets and some sort of protection from stones but it sits in there perfect .

Oh and be carefull how you run any braided hoses as the have a tendacy to eat through anything that it rubs against .

what belt did you use thats shorter?

[Mudslinger]

what belt did you use thats shorter?

most motor factors will sell belts all different lengths

[Andrew Cooke]

most motor factors will sell belts all different lengths

indeed, the part number is usually the length in mm

[Markey Mark (BD)]

Raj mate, i've run the intercooler pipe through the inner arch just behind the headlight on mine, makes it easier to route from the intercooler to inside the engine bay. Only trouble you might come across is getting it over all the pipework you have around the waterpump area, i got round it with my old 5 by repositioning a few things.
Its a bit easier with my engine now as the throttle body is right next to the headlight now so nice short run.

[raj]

im assuming that you can only go so far with a shoter belt? im sure the gap is around 10mm from the back of the alternator to the engine block.?

[raj]

Raj mate, i've run the intercooler pipe through the inner arch just behind the headlight on mine, makes it easier to route from the intercooler to inside the engine bay. Only trouble you might come across is getting it over all the pipework you have around the waterpump area, i got round it with my old 5 by repositioning a few things.
Its a bit easier with my engine now as the throttle body is right next to the headlight now so nice short run.

mark, you dont happen to have any pics of it do you? im wanting to know how close to the headlamp you drilled?
also can i ask what you used to cut the section out of the arch? ive got a small angle grinder and cant see that doing the job from the top or bottom maybe a hole cutter.?

[Markey Mark (BD)]

mark, you dont happen to have any pics of it do you? im wanting to know how close to the headlamp you drilled?
also can i ask what you used to cut the section out of the arch? ive got a small angle grinder and cant see that doing the job from the top or bottom maybe a hole cutter.?

I have but oi think its on my old computer, got to swap them alll over at some point.

I used an air-saw so i cut a nice square out of the panel, i cut it up to the headlight panel.

[raj]

I have but oi think its on my old computer, got to swap them alll over at some point.

I used an air-saw so i cut a nice square out of the panel, i cut it up to the headlight panel.

if only i had an air saw

[Markey Mark (BD)]

If you go buy a hole saw you could do it, i'm sure they sell one about 2"-2.25" from a tool suppilers.

[Andrew Cooke]

the metal is so thin there you can probably cut it out with your nail clippers.

[raj]

If you go buy a hole saw you could do it, i'm sure they sell one about 2"-2.25" from a tool suppilers.

ill give the circular a try first and see how it goes. if not then its hire a reciprocating saw to finish the job

mark i can see the cutout youve done on your red 5. from looking at it the hole looks too far to the outside?? i would have thought the closer to the engine side the better as it would keep the pipework further away from the wheels..?

[Markey Mark (BD)]

Where i have cut the hole there is plenty of clearence between the wheel and the pipework, to be honest it doesn't matter where you cut it weather its closest to the chassis leg or the arch just make sure you cut it as close as you can to the headlight.
I have modified the panel below the headlight too so it gives even more clearence and also makes it possible to have a straight boost pipe run rather then having a bend under there. I haven't got a pic of that but can get one for you if you want.

[raj]

Where i have cut the hole there is plenty of clearence between the wheel and the pipework, to be honest it doesn't matter where you cut it weather its closest to the chassis leg or the arch just make sure you cut it as close as you can to the headlight.
I have modified the panel below the headlight too so it gives even more clearence and also makes it possible to have a straight boost pipe run rather then having a bend under there. I haven't got a pic of that but can get one for you if you want.

yes mate, if you can get me a pic of the modded area that would be great thanks.

[Markey Mark (BD)]

yes mate, if you can get me a pic of the modded area that would be great thanks.

Will do mate, if you can wait what i will do is mock up the pipe run on the car next weekend so it shows you abit better what i did plus it shows you how it will look too.

I'll also try get the old photo's of my blue car too with the intercooler pipework too to show you it with the C1J fitted.

[raj]

Will do mate, if you can wait what i will do is mock up the pipe run on the car next weekend so it shows you abit better what i did plus it shows you how it will look too.

I'll also try get the old photo's of my blue car too with the intercooler pipework too to show you it with the C1J fitted.

ok mate will wait for your reply just dont go and forget

[Markey Mark (BD)]

ok mate will wait for your reply just dont go and forget

I'll try not too, i need to get the 5 out the garage anyway so i'll do it then.

[Mike Wilson@ PCS]

plenty off space for 50mm pipe beside alternator with keeping original sized belt

[gttjames]

indeed, the part number is usually the length in mm

got any links to some, or better still part number?

[youngscottie]

it should fit

[raj]

erm if you re-read my question/or look at my pics youll see i have no space to run it at the side of the alternator as my rad is right up against it.

im going to attack the wheel arch tomorrow and hope for the best

[Andrew Cooke]

if you make a round hole you could consider swaging it, it'll stop the metal being all floppy.

http://www.motorsport-tools.com/inde...415ed452244982

you could try making a gizmo out of wood.

[raj]

if you make a round hole you could consider swaging it, it'll stop the metal being all floppy.

http://www.motorsport-tools.com/inde...415ed452244982

you could try making a gizmo out of wood.

that would make it look good, but think ill opt for using rubber o-ring to keep it tidy. i dont tink a hole will make the metal flimsy around there as they'll be plenty of metal left around the hole.

[rs250nut]

as my build is nearing completion, i have one last job left to do. and that being making a pipe run for the front mount intercooler.

now the turbo to i.c run i can sort myself.

im just stumped on how ill route the carb to i.c run

i have no space to go over the alternator as i have an inline oil stat sitting there.
i cant see the pipe work getting inbetween the chassis and alternator belt either.!

the only idea i have thought of is if i drill a large enough hole just behind the o/s headlight for the pipework to pass through and reach the i.c with a few bends!

any other ideas welcome.

here are some pics of the engine bay -

That looks the dogs under the bonnet Raj good work matey, what intercooler is that as I have the same one?

[gttjames]

it should fit

That looks good mate, what size is that intercooler and where did you get it from? did you have to loose much on the front bumper and can you still keep the foggy's?

[raj]

That looks the dogs under the bonnet Raj good work matey, what intercooler is that as I have the same one?

if you have the same one you tell me

[rs250nut]

if you have the same one you tell me

If I knew I would not have askedIt came with the car I brought

[Big Steve - Raider]

Looks like a heave ho intercooler??

[raj]

If I knew I would not have askedIt came with the car I brought

jeez bud, dont get stroppy its cooler i bought off ebay. i cant remember the seller sorry, its exactly the same as this one though i.c

[raj]

Looks like a heave ho intercooler??

heave ho = evo..?

[Big Steve - Raider]

Yeah sorry, thats a Mart-ism

[Mart]

Found a pic

Interesting i/c outlet run...