550x140x65 IC Fitting

[jure]

After watching and examining few pics and about a hour of measuring I decided to give it a try. Mission was to fit universal IC dimensions 550mm long, 140mm high and 65mm thick without cutting even smallest part of slam panel. And... I did it!

Two modification are required. You need to cut little bit of towing eye and there is no space for lower bumper brackets but IC is holding bumper even more tight than with those same brackets. No BS. There is also space for the fog lights but I'm after white ones so It will be like this for week or two.

Here are few pics and if you need any info, just ask. I know this isn't rocket science but think that lot of people would like to do the same thing.

[gttjames]

good work.

Am in the process of fitting a 550x180x65, so have cut the bottom strip off the slam panal. Just gota pipe it all up.

Put the bumper back on and dont even have to cut any of it if i didnt want, but might loose abit maybe

[gttjames]

heres mine so far

[tom t]

is that gana fit behind the standard bumper james without it being cut? and with fog lights? cheers

[rs250nut]

I need an intercooler that will fit behind a standard front bumper, that looks quite good

[jure]

Both (James and mine) fit under the standard bumper without cutting. You can fit foglights if you use 90 degree pipe on inlet and outlet of the IC just like James did.

[gttjames]

am strugerling...

intecooler fits ok, just the 90 bend is touching the back of the foglight bit, and iv allready had to cut off the bottom bumper mounts.

Looks like if i get the bumper on, when fitting foglights the screw will go into the hose?

any ideas?

[gttjames]

After watching and examining few pics and about a hour of measuring I decided to give it a try. Mission was to fit universal IC dimensions 550mm long, 140mm high and 65mm thick without cutting even smallest part of slam panel. And... I did it!

Two modification are required. You need to cut little bit of towing eye and there is no space for lower bumper brackets but IC is holding bumper even more tight than with those same brackets. No BS. There is also space for the fog lights but I'm after white ones so It will be like this for week or two.

Here are few pics and if you need any info, just ask. I know this isn't rocket science but think that lot of people would like to do the same thing.

i see, you have mangaged to get yours to sit further back than mine.

i cant do that though as its allready right back on the crossmember

[jantheeven]

Great info Jure!

Where did you buy the IC?

[jure]

Mine is from Wiltec. It is same as this one http://cgi.ebay.co.uk/NEW-Front-moun...3A1|240%3A1318

but there is plenty of sellers around heaving same dimensions ICs. It is great quality product

[jantheeven]

Mine is from Wiltec. It is same as this one http://cgi.ebay.co.uk/NEW-Front-moun...3A1|240%3A1318

but there is plenty of sellers around heaving same dimensions ICs. It is great quality product

Good stuff! But does this IC really cool much better than my double capacity alloy unit? Yours doesn't look too big... but I'm sure it catches more wind than an IC in the o.e. position, right?

[jure]

There was great article about IC capacities on the old site. I remember that standard GTT was around 2.8 litres, double capacity ones were from 4.2 to 5.4 (i think) and mine is 5 litres. I decided on this setup because of, as you mentioned, better air flow and I can automatcly place air filer just behind the grill. Also, few months ago you couldn't buy double capacity IC (new) for less than 300 quids and this one cost next to nothing.

I made some calculation and think that I got right size of the IC. I took in to consideration increase of the boost, size of the turbo, reving and inlet/outlet modifications. It wasn't something complicated but only how much each thing was increased in percentage and I increased capacity of the IC accordigly.

[Matt Cole]

Chaps this is mine which i need to get behind the front bumper withough hacking it to bits. Now cutting the front cross member is this wise??

The size is 595 (hose outlet end to end) x 180 x 63. Core size is 545mm

[gttjames]

Did like you did jure, and trimmed abit of the towing eye bracket. Is still tight with the hoses on the back of the fog bit on the bumper, to get the fogs in will have to do abit more modding, looks possible though.

Have got a silicone 90deg reducer, so its 57mm off the ic outlets, am think if i got some straight reducers that go 57-51mm off the ic outlet, then onto a 51mm alloy 90 deg bend will this be any better?

[jantheeven]

Jure... where did you get that oil cooler mate? And the braided feed lines?

[MR TURBO]

Jure... where did you get that oil cooler mate? And the braided feed lines?

This looks quite similar http://www.k-tecracing.com/show_prod...p?id=363&pic=1

[jantheeven]

I think that K-Tec unit is smaller... and probably more expensive too
But I do think you don't really need a bigger one than the K-Tec thing... am I correct?

[MR TURBO]

looks a good enough size to me

[jure]

Jure... where did you get that oil cooler mate? And the braided feed lines?

It is Mocal universal 13 row cooler and lines were made by local hydraulic specialist shop. Cost in total 80 quids

[jantheeven]

heres mine so far

Mate... that front member is certainly modified. Did you buy the car like this or what did you do with it? Compare it to Jure's cross member...

[gt_maxer]

New poster! (less than 10 posts)

go grill mounted, much easier, no modifying required and less pipe run.

[jantheeven]

New poster! (less than 10 posts)

go grill mounted, much easier, no modifying required and less pipe run.

That's an option... but I don't like the idea of the i/c partially blocking the air flow to the rad

[MR TURBO]

That's an option... but I don't like the idea of the i/c partially blocking the air flow to the rad

Dave Kirk says this is not a problem during our convo about GMIC's

[jantheeven]

Still not convinced...

Opinions people??

[gttjames]

Mate... that front member is certainly modified. Did you buy the car like this or what did you do with it? Compare it to Jure's cross member...

it was the same as jures before i cut it.

i removed the bottom strip off it, and most off the 2 plates that are on jures, left the corner though

[MR TURBO]

700mmx140mmx65mm : This is the size of mine being done

[jantheeven]

700mmx140mmx65mm : This is the size of mine being done

I think I'll also go for that size... any bigger is useless when you don't want to hack up your standard bumper imo. Plus I really don't want to cut the cross member in any way...

[MR TURBO]

I think I'll also go for that size... any bigger is useless when you don't want to hack up your standard bumper imo. Plus I really don't want to cut the cross member in any way...

Its apparently its some new narrow style and with luck my bumper will fit neatly i did want to go Grill mounted but my outlets come out of the sides rather than the back so it just makes it a long winded job

[jure]

I think I'll also go for that size... any bigger is useless when you don't want to hack up your standard bumper imo. Plus I really don't want to cut the cross member in any way...

Go for it mate. If double capacity can cope with 25 psi+ there is no reason why this one, which is in way better position, couldn't.

[MR TURBO]

Hey guys anybody got an birds eye view of a FMIC fitted

[MR TURBO]

Hey guys anybody got an birds eye view of a FMIC fitted

PLEASE ANYBODY

[jure]

Sorry I don't have but can tell you that IC is in line with slam panel in mm. Hope this help.

[MR TURBO]

Sorry I don't have but can tell you that IC is in line with slam panel in mm. Hope this help.

The garage its in the guy cant work out how to route the pipe from the carb top down

[MR TURBO]

Or any pics of the piping and how it routes from the carb top over alternator/water pump etc....

[gttjames]

heres how i did mine.
2x90 degs for round subframe

to a straight bit of pipe, to a 90deg over alternator

then to carb top

[MR TURBO]

James you are a life saver

[Nick k]

ebay.co.uk/FRONT-MOUNT-UNIVERSAL-INTERCOOLER-PUNTO-STARLET-TURBO item 220349499994

£59 + £13 postage.

Brand New in the box
Aluminium Bar and Plate Intercooler
Core size: 540mm x 140mm x 65mm
End to end 690mm/27"
2.5"(64mm) Inlet and Outlet
Max Horsepower Capacity

What do you think to that?

Length??

[MR TURBO]

ebay.co.uk/FRONT-MOUNT-UNIVERSAL-INTERCOOLER-PUNTO-STARLET-TURBO item 220349499994

£59 + £13 postage.

Brand New in the box
Aluminium Bar and Plate Intercooler
Core size: 540mm x 140mm x 65mm
End to end 690mm/27"
2.5"(64mm) Inlet and Outlet
Max Horsepower Capacity

What do you think to that?

Length??

Link is dead

[MR TURBO]

This is the one Tarmac is talking it is very similar to mine if not same only dimensions i think but yes it should be cool sir : http://cgi.ebay.co.uk/ws/eBayISAPI.d...3D50%26fvi%3D1

[Nick k]

This is the one Tarmac is talking it is very similar to mine if not same only dimensions i think but yes it should be cool sir : http://cgi.ebay.co.uk/ws/eBayISAPI.d...3D50%26fvi%3D1

Yea thats it. See on Jure's pictures in first post. Can u it be mounted so the outlets are at the top (closer to the cross member) to give more room for fog lights??

[MR TURBO]

I'd of thought either way just depends on your pipe run

[jure]

Yea thats it. See on Jure's pictures in first post. Can u it be mounted so the outlets are at the top (closer to the cross member) to give more room for fog lights??

You could but then IC would stick little more to the front since subframe would touch IC inlet/outlet (see pic1 post1). I didn't try but you could have problem IC hitting the fins on the front bumper if you mount it with inlet/outlet up.

[jure]

WHAT DO YOU NEED TO FIT 550x140x65 INTERCOOLER

Of course, you need universal front mounted intercooler that has dimensions:
-550mm width
-140mm height
-65mm thick

Overall length (from inlet to outlet) is 700mm. Inlet and outlet diameter is 60mm.

I will start in direction TURBO - IC - CARB.

Turbo outlet...

1. 90 deg. 50mm hose
2. straight aluminium pipe (8-10cm)
3. 90 deg. 50mm hose
4. straight aluminium pipe (8-10cm)
5. 90 deg. 50mm hose
6. straight aluminium pipe (8-10cm)
7. 90 deg. 60mm to 50mm hose

...we reached IC inlet...IC...IC outlet...

8. 90 deg. 60mm to 50mm hose
9. straight aluminium pipe (8-10cm)
10. 90 deg. 50mm hose
11. straight aluminium pipe (20-25cm)
12. 90 deg. 50mm hose
13. straight aluminium pipe (8-10cm) or aluminium "T" piece for fitting dump valve
14. straight 50mm hose

...and we are on our final destination - carb! Happy boosting

To summarize and give approx prices:

1x universal intercooler = 70 pounds
5x 90 deg. 50mm silicon hose (5x12.00) = 60 pounds
5x straight aluminium pipe - short (5x6.00) = 30 pounds
2x 90 deg. 60mm to 50mm silicon hose (2x20.00) = 40 pounds
1x straight 50mm silicone hose (1x4.00) = 4 pounds
1x straight aluminium pipe - long (1x8.00) = 8 pounds
16x hose clips/clamps 45mm to 65mm (16x1.50) = 24 pounds

IN TOTAL: 236 pounds without delivery. These days most of the tuning houses or eBay sellers have each one of the items listed, so shipping won't be more than 20-25 pounds. You can lower final price by buying 1m of aluminium pipe and cutting it yourself but then you will not have small "dents" on the ends of pipes which can cause hose slipping.

Hope it helped

[Sy5GTT]

I couldn't get a 90 deg elbow in front of the alternator ( angle too sharp) so used 2 45deg elbows. I had to cut them off (just after the bend on one side) and join the cut bits together with a bit of alloy tube. It still gives you a 90deg bend but fits a lot better.

[tom t]

awesome last post jure i will be using that for when i actually have some money. work is pretty dead at the mo.

[MR TURBO]

I recieved the call i'd been waiting for this morning that my little bad boy was ready for pick up WOO bloody WHOO......I was beginning to think it was actually rocket science fitting one of these.......But then again thats why I never take my car to garages no more lucky the guy in the garage is a friend of mine and it'll only be drink money handed over as i already had my own piping just had to adapt the ends i hope...I can't wait to start my own garage But hey happy days and thank you all for your help and advice.....I'll hopefully get some pics up

[Nick k]

WHAT DO YOU NEED TO FIT 550x140x65 INTERCOOLER

Of course, you need universal front mounted intercooler that has dimensions:
-550mm width
-140mm height
-65mm thick

Overall length (from inlet to outlet) is 700mm. Inlet and outlet diameter is 60mm.

I will start in direction TURBO - IC - CARB.

Turbo outlet...

1. 90 deg. 50mm hose
2. straight aluminium pipe (8-10cm)
3. 90 deg. 50mm hose
4. straight aluminium pipe (8-10cm)
5. 90 deg. 50mm hose
6. straight aluminium pipe (8-10cm)
7. 90 deg. 60mm to 50mm hose

...we reached IC inlet...IC...IC outlet...

8. 90 deg. 60mm to 50mm hose
9. straight aluminium pipe (8-10cm)
10. 90 deg. 50mm hose
11. straight aluminium pipe (20-25cm)
12. 90 deg. 50mm hose
13. straight aluminium pipe (8-10cm) or aluminium "T" piece for fitting dump valve
14. straight 50mm hose

...and we are on our final destination - carb! Happy boosting

To summarize and give approx prices:

1x universal intercooler = 70 pounds
5x 90 deg. 50mm silicon hose (5x12.00) = 60 pounds
5x straight aluminium pipe - short (5x6.00) = 30 pounds
2x 90 deg. 60mm to 50mm silicon hose (2x20.00) = 40 pounds
1x straight 50mm silicone hose (1x4.00) = 4 pounds
1x straight aluminium pipe - long (1x8.00) = 8 pounds
16x hose clips/clamps 45mm to 65mm (16x1.50) = 24 pounds

IN TOTAL: 236 pounds without delivery. These days most of the tuning houses or eBay sellers have each one of the items listed, so shipping won't be more than 20-25 pounds. You can lower final price by buying 1m of aluminium pipe and cutting it yourself but then you will not have small "dents" on the ends of pipes which can cause hose slipping.

Hope it helped

All the above listed i have found on ebay:

Mr Silicone

5 x 90 deg silicone 51mm£11.06 (2.95) postage {blue/black/red}
2 x 63 - 51mm reducers £13.76 (2.45)
1 x 51mm silicon length 1m £18.56 (2.45)

Autoperformanceonline

5 x 51mm Alum pipe 100mm length £6.05 (1.95)
1 x 51mm Alum pipe 300mm Length £9.99 (2.45)
2 x 10(PK) 50 - 70mm clips £4.45 (1.95)

2fast2cool2

Intercooler
540mm x 140mm x 65mm £59.00 (12.95)

Grand Total £254.47.

Thats without multiple postage. So could be cheaper. All uk suppliers.

Bring on the front mount!!

[MR TURBO]

Just picked up my 5 the FMIC looks good and fits snugly behind my bumper no cutting......Gave it a little run back from the garage and it feels nice and sounds better than before

[Blick]

finaly finished my front mount 2day!!! can still fit my standard front grill also.... bonus

[Markey Mark (BD)]

finaly finished my front mount 2day!!! can still fit my standard front grill also.... bonus

Thats quite a good way of using the original boost hose off the carb, never thought of that