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  1. #1
    Non-member jure's Avatar
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    550x140x65 IC Fitting

    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.
    Attached Images Attached Images      
    Last edited by jure; 12-01-2009 at 21:53.

  2. #2
    Non-member gttjames's Avatar
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    Re: 550x140x65 IC Fitting

    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

  3. #3
    Non-member gttjames's Avatar
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    Re: 550x140x65 IC Fitting

    heres mine so far


  4. #4
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    Re: 550x140x65 IC Fitting

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

  5. #5
    Non-member rs250nut's Avatar
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    Re: 550x140x65 IC Fitting

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

  6. #6
    Non-member jure's Avatar
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    Re: 550x140x65 IC Fitting

    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.

  7. #7
    Non-member gttjames's Avatar
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    Re: 550x140x65 IC Fitting

    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?

  8. #8
    Non-member gttjames's Avatar
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    Re: 550x140x65 IC Fitting

    Quote Originally Posted by jure View Post
    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

  9. #9
    Non-member jantheeven's Avatar
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    Re: 550x140x65 IC Fitting

    Great info Jure!

    Where did you buy the IC?

  10. #10
    Non-member jure's Avatar
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    Re: 550x140x65 IC Fitting

    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

  11. #11
    Non-member jantheeven's Avatar
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    Re: 550x140x65 IC Fitting

    Quote Originally Posted by jure View Post
    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?

  12. #12
    Non-member jure's Avatar
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    Re: 550x140x65 IC Fitting

    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.

  13. #13
    Committee, Moderator Matt Cole's Avatar
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    Re: 550x140x65 IC Fitting

    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
    Attached Images Attached Images  
    Last edited by Matt Cole; 16-01-2009 at 14:24.

  14. #14
    Non-member gttjames's Avatar
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    Re: 550x140x65 IC Fitting

    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?

  15. #15
    Non-member jantheeven's Avatar
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    Re: 550x140x65 IC Fitting

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

  16. #16
    Non-member MR TURBO's Avatar
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    Re: 550x140x65 IC Fitting

    Quote Originally Posted by jantheeven View Post
    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

  17. #17
    Non-member jantheeven's Avatar
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    Re: 550x140x65 IC Fitting

    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?

  18. #18
    Non-member MR TURBO's Avatar
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    Re: 550x140x65 IC Fitting

    looks a good enough size to me

  19. #19
    Non-member jure's Avatar
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    Re: 550x140x65 IC Fitting

    Quote Originally Posted by jantheeven View Post
    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

  20. #20
    Non-member jantheeven's Avatar
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    Re: 550x140x65 IC Fitting

    Quote Originally Posted by gttjames View Post
    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...

  21. #21
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    Re: 550x140x65 IC Fitting

    New poster! (less than 10 posts)

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

  22. #22
    Non-member jantheeven's Avatar
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    Re: 550x140x65 IC Fitting

    Quote Originally Posted by gt_maxer View Post
    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

  23. #23
    Non-member MR TURBO's Avatar
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    Re: 550x140x65 IC Fitting

    Quote Originally Posted by jantheeven View Post
    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

  24. #24
    Non-member jantheeven's Avatar
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    Re: 550x140x65 IC Fitting

    Still not convinced...

    Opinions people??

  25. #25
    Non-member gttjames's Avatar
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    Re: 550x140x65 IC Fitting

    Quote Originally Posted by jantheeven View Post
    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

  26. #26
    Non-member MR TURBO's Avatar
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    Re: 550x140x65 IC Fitting

    700mmx140mmx65mm : This is the size of mine being done

  27. #27
    Non-member jantheeven's Avatar
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    Re: 550x140x65 IC Fitting

    Quote Originally Posted by MR TURBO View Post
    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...

  28. #28
    Non-member MR TURBO's Avatar
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    Re: 550x140x65 IC Fitting

    Quote Originally Posted by jantheeven View Post
    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

  29. #29
    Non-member jure's Avatar
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    Re: 550x140x65 IC Fitting

    Quote Originally Posted by jantheeven View Post
    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.

  30. #30
    Non-member MR TURBO's Avatar
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    Re: 550x140x65 IC Fitting

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

  31. #31
    Non-member MR TURBO's Avatar
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    Re: 550x140x65 IC Fitting

    Quote Originally Posted by MR TURBO View Post
    Hey guys anybody got an birds eye view of a FMIC fitted
    PLEASE ANYBODY

  32. #32
    Non-member jure's Avatar
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    Re: 550x140x65 IC Fitting

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

  33. #33
    Non-member MR TURBO's Avatar
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    Re: 550x140x65 IC Fitting

    Quote Originally Posted by jure View Post
    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

  34. #34
    Non-member MR TURBO's Avatar
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    Re: 550x140x65 IC Fitting

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

  35. #35
    Non-member gttjames's Avatar
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    Re: 550x140x65 IC Fitting

    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

  36. #36
    Non-member MR TURBO's Avatar
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    Re: 550x140x65 IC Fitting

    James you are a life saver

  37. #37
    Non-member Nick k's Avatar
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    Re: 550x140x65 IC Fitting

    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??

  38. #38
    Non-member MR TURBO's Avatar
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    Re: 550x140x65 IC Fitting

    Quote Originally Posted by Tarmac trasher - Nick View Post
    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

  39. #39
    Non-member MR TURBO's Avatar
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    Re: 550x140x65 IC Fitting

    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

  40. #40
    Non-member Nick k's Avatar
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    Re: 550x140x65 IC Fitting

    Quote Originally Posted by MR TURBO View Post
    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??

  41. #41
    Non-member MR TURBO's Avatar
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    Re: 550x140x65 IC Fitting

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

  42. #42
    Non-member jure's Avatar
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    Re: 550x140x65 IC Fitting

    Quote Originally Posted by Tarmac trasher - Nick View Post
    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.

  43. #43
    Non-member jure's Avatar
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    Re: 550x140x65 IC Fitting

    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

    Attached Images Attached Images      
    Last edited by jure; 23-01-2009 at 13:56.

  44. #44
    Non-member Sy5GTT's Avatar
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    Re: 550x140x65 IC Fitting

    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.

  45. #45
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    Re: 550x140x65 IC Fitting

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

  46. #46
    Non-member MR TURBO's Avatar
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    Re: 550x140x65 IC Fitting

    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

  47. #47
    Non-member Nick k's Avatar
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    Re: 550x140x65 IC Fitting

    Quote Originally Posted by jure View Post
    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!!
    Last edited by Nick k; 23-01-2009 at 21:06.

  48. #48
    Non-member MR TURBO's Avatar
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    Re: 550x140x65 IC Fitting

    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

  49. #49
    Non-member Blick's Avatar
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    Re: 550x140x65 IC Fitting

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


  50. #50
    Non-member Markey Mark (BD)'s Avatar
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    Re: 550x140x65 IC Fitting

    Quote Originally Posted by Blick View Post
    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

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