Hi while my engine is out I thought about upgrading my chargecooler to a RS 500 spec intercooler.

What is involved?

cheeRS Dave.

 

Getting one that is designed for the Escort and not a Sierra / Sapphire / drilling the cross member to accept the intercooler and providing you are using the standard size hoses, that's about it.

 

hi mike does it fit in front of or behind the radiator and will there still be space for my swirl pot and will I have to change any hoses?

Dave.

 

Dave,

It deffo fits in front of the water radiator. There will be enough space for the swirl pot, and you can use the standard I/C outlet to throtle hose BUT IMO * the turbo to I/C hose needs to be a special one........main problem is the proximity of the alternator, it will tend to rub on a standard hose and as the engine moves quite a lot, it wont be long before is wears a hole in the hose. I will post some pics up soon.

* Are you using a T4 turbo???? If not than you will need a special hose anyway.

 

Special stainless angled elbow was made up, then the standard (or Samco/Roose hose) RS500 hose is cut and attached to the elbow, thia allows plenty of adjustment to give clearance away from the alternator:

 

Genuine 500 i/c, you have to cut off the turbo side spout and rotate it outwards 180 degrees and weld the bugger back on!! Then you get a pair of hoses from roosemotorsport i.e. 3" to standard esc cossie size turbo/throttle body!! As for mounting it, there are some holes just in front of the radiator mounting points which work a treat!!!

 

thanks lads I don't think I will be fitting a genuine RS500 one ( hard to get hold of ) I was thinking of getting the next best one from the Performance Ford trial what they did, but I can't find a copy of the magazine anywere

Dave.

 

You're right, I only found one today!!!! It's the Lord Lucan of car magazines!!!

I really should subscribe!!!

 

i got a radtec one and its easy to fit, contact me if you want one as i have a deal set up with them for rs members

 

Definitely go for the Radtec Racing one (specifying Escort Cosworth fitment), where the angle of the dangle (turbo to intercooler pipe) is modified to suit the Escort .

 

I have used the holes already drilled just in front of the rad mounts, but had to bend these back a bit.

 

what happens to the little water pipe that goes into the chargecooler do you just blank it of ?

Dave.

 

You have two choices - fit a u-bend to feed it back to the thermostat or change the metal pipe that runs along the side of the engine to a Sapphire item (which doesn't have the "swan neck") and heat the connection in the thermostat and rotate it 180° so that it is facing the correct way. Obviously the former is the easiest.

 

anyone got any pictures of mikes modification?

Dave.

 

I have a pic of the "U" bend pipe..........will upload it soon......take a few mins.....

 

 

Come and see us at National day next Sunday (22nd) We will offer great deals to all RS and PF members

 

Doug Stirling, Where did you get that bit of pipe? How much?

 

Steve, I fitted all new water hoses to my car (standard Ford)...well one of the "old" hoses, cant remember witch one, allready has a bend in it at one end 90° (ish), so I cut that bit off, bent it round a bit more making sure it was'nt going to kink - and thats what I fitted.

Cheapskate of the year award to me

 

Mate, have you seen mine?

I will have to take a look around for a bit of pipe I guess...