qed296

Just sorted all the parts and blow me it won't fit now.

seems the intercooler pipe to the turbo is to large, wrong shape....not really sure as the box won't sit down onto the inner wing as the front mount hits the pipe.

It has a XSPOWER rs500 style inter cooler with pj silicone hoses that look to be about 70mm dia.

any ideas or suggestions as to a hose that accommodates the o/e airbox.

cheers

Caddyshack

Can you stick up a picture of the problem. People like Ggr sell custom hoses

qed296

Trying....photobucket seems to be struggling

any ideas on a good image hosting site plz....

Caddyshack

You don't need a hosting site, this site does it for you, I will post up a pic of what to press.

Caddyshack

Press the yellow icon and then browse your phone or computer.

qed296

Just a test pic....the washer bottle has been dropped out for a bent neck type....I'm off out the garge to get some decent pictures. Thanks for the help...pictures make things so much easier to explain

Caddyshack

Cool, yes we will get it sorted now as loads on here will have solved the problem

qed296

Didn't realise till yesterday, I work in Lincoln next to Roose, there sorting me a 70mm to standard for the airbox in matt black o/e colour....hope to do them all now

Caddyshack

Yeah, roose are great, I have them on mine

qed296

Hose in place

qed296

Hose off, intercooler end is 60mm o/d .....turbo housing is 50mm/52mm

qed296

Now with an original hose laid over the blue hose its clear the extra material on the bend is the problem....i have put the o/e hose onto the turbo housing and it does create exra room for the airbox to fit in....

Caddyshack

Can you heat it up and make the bend tighter?

qed296

Is that possible???

I would like them all in black eventually, I'm happy to cut both up to make a template, 60mm blue end from the intercooler should sleave over the orange to make a good guide for making what' really needed.

jason_nike

I've been thinking about refitting my standard airbox too, think OEM looks better

qed296

Second that, my goal is to go o/e looking under the bonnet...

intercooler & radiator will be sprayed/coated black too for the o/e look.

nice colour sapph Jason.....

1374lee

iTrader: (11)

Yep, airbox has just been fitted back on my car,the turbo to i/cooler hose is very tight to the side of the airbox, I have a T34 turbo fitted.

Thanks. Lee.

qed296

What hose are you using?
The intercooler is 60mm to 50mm on the turbo (0.48)

qed296

A bit of an update,

After taking off the heat shield bracket and flipping it the correct way and removing the hose from the intercooler the airbox dropped straight into position.

After fighting the arch liner and using new nuts and bolts it all came together nicely.

surprisingly with the base of the airbox in place the intercooler hose went back on with no issues.

The airbox (60mm) to turbo (70mm) did need trimming about 50mm off the airbox end and 25mm off the turbo end for good fit but that's getting replaced with a Roose oe black item and now knowing the intercooler hose fits the whole lot can be done.

Question, on the amal valve there is a small hose not connected to anything.....should it be??

Is the 8mm tube off the airbox lid surposed to be connected to anything??

bigdel

Dunno if it's different for your car, but on my 3dr the left hose goes to the airbox, the centre goes to the actuator and the right one goes to the compressor housing

bigdel

Oh, and the water hoses are Roose OE black silicone

qed296

Thanks for this, just seems odd not to connect to anything.

qed296

Thanks for this, just seems odd not to connect to anything.

qed296

Jules44

Mine is exactly the same as that 1988 2wd

qed296

Now I'm confused, this redtop with blue slam panel looks to be plumbed in the same as mine with the coloured lines on...or are my eyes plain trick on me....Bigdels looks to be a different arrangement...

bigdel

Well, im off to connect mine up properly. Thought the amal valve wasn't working so replumbed it to run direct, but it looks like the pipes were wrongly routed after all. Maybe I should have read my book...
here's your definitive answer

qed296

Thanks Bigdel....just stumbled across a thread from 2011 by stu@ m s developments on this subject.

quote :

C - compressor
W - wastegate
R - airbox

I also managed to find the vac pipe from the airbox that was missing on ebay tonight.

bigdel - what's the book you have there and is it still available ??

bigdel

It's the Ford workshop manual for the Saff & 3dr Cosworth
Bought it years ago from my local Ford dealer. Don't think they're available there now though.
Some on EBay but they aren't cheap
http://www.ebay.co.uk/itm/183055104157

Jules44

You can download the manuals from here http://www.racetuners.com/julian-god...-pages/2789-2/