New intercooler / rad set-up
11-09-2005, 08:11 PM
#1
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New intercooler / rad set-up
Pics of my new intercooler and radiator set-up.
This system is designed as a direct replacement for the OE spec. The radiator sits in the usual place, but the intercooler sits above the rad directly behind the front grill. They are both constructed so that there is no cutting or drilling of the car. They are designed so that the intercooler uses the existing radiator top mounting holes in the rear of the slam panel.
The only items which need modifications are the charge-carrier & the hoses.
The cooler is a Cossie 4x4 system with the end caps turned. The radiator is a totally custom-made rad which keeps the original capacity, but is obviously shorter in height, but wider to compensate. I need to get 2x slimline fans to run with. As the cooler now runs left to right (instead of top to bottom), I have a reverse charge-carrier to fit also.
The idea is to get some stainless piping made up to go between the ends & use a piece of silicon on each end, as opposed to totally making the hoses up mix & match style. I feel it will be a better finish to the job this way.
The top water hose also need slightly lengthening due to the fact the right-hand intercooler hose has to go down past the induction kit & under to the turbo. The new water pipe will run behind the airfilter, then run down below this boost hose.
Pics of my set-up:
Pics of the set-up fitted to another car: Here you can see that the boost hose is in a conflicting place with the water hose...hence the reason for alternate routing.
Pic of reverse carrier & multi-hose set-up.
Thanx to Scott R for the bits & MJC for the original inspiration & bottom pics
This system is designed as a direct replacement for the OE spec. The radiator sits in the usual place, but the intercooler sits above the rad directly behind the front grill. They are both constructed so that there is no cutting or drilling of the car. They are designed so that the intercooler uses the existing radiator top mounting holes in the rear of the slam panel.
The only items which need modifications are the charge-carrier & the hoses.
The cooler is a Cossie 4x4 system with the end caps turned. The radiator is a totally custom-made rad which keeps the original capacity, but is obviously shorter in height, but wider to compensate. I need to get 2x slimline fans to run with. As the cooler now runs left to right (instead of top to bottom), I have a reverse charge-carrier to fit also.
The idea is to get some stainless piping made up to go between the ends & use a piece of silicon on each end, as opposed to totally making the hoses up mix & match style. I feel it will be a better finish to the job this way.
The top water hose also need slightly lengthening due to the fact the right-hand intercooler hose has to go down past the induction kit & under to the turbo. The new water pipe will run behind the airfilter, then run down below this boost hose.
Pics of my set-up:
Pics of the set-up fitted to another car: Here you can see that the boost hose is in a conflicting place with the water hose...hence the reason for alternate routing.
Pic of reverse carrier & multi-hose set-up.
Thanx to Scott R for the bits & MJC for the original inspiration & bottom pics
28-02-2006, 06:20 PM
#3
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Got my charge-carrier back for the fit. Had the bottom end turned 180-ish degrees. Thanx to Scott R from RSOC for sorting this for me.
Now been worked around the bottom turned-end. Got rid of two nobbly bits from the side, then smoothed off the two side edges where the halves are joined. Had a think, and decided to smooth off the fins, just leaving the badge in the centre.
Got a couple of ideas on how to highlight the badge, but undecided yet.
1: paint the whole lot anthracite like the rocker, then polish off the badge lip ("Ford" and outer oval).
2: paint the badge blue, powder coat in anthra, then polish off lip again.
3: paint badge blue, powder coat in plain silver: standard colour-ish, then polish lip as before.
Maybe not the best pic: shows all my file marks, but once it's painted will look spot-on
Now been worked around the bottom turned-end. Got rid of two nobbly bits from the side, then smoothed off the two side edges where the halves are joined. Had a think, and decided to smooth off the fins, just leaving the badge in the centre.
Got a couple of ideas on how to highlight the badge, but undecided yet.
1: paint the whole lot anthracite like the rocker, then polish off the badge lip ("Ford" and outer oval).
2: paint the badge blue, powder coat in anthra, then polish off lip again.
3: paint badge blue, powder coat in plain silver: standard colour-ish, then polish lip as before.
Maybe not the best pic: shows all my file marks, but once it's painted will look spot-on
28-02-2006, 07:01 PM
#4
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How much did you pay for the radiator? Seems like a good concept if the rad will cool aswell (or as bad) as the original radiator. I'm looking for radiator upgrade so I'm fitting a non rst escort mk4 rad, it's atleast 25% bigger, and with my intercooler setup I'm pretty sure it will fit.
A 4x4 cos intercooler will definitly do the job for you.
A 4x4 cos intercooler will definitly do the job for you.
01-03-2006, 10:34 AM
#7
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Rallyesport You'll have to ask Scott R ( https://passionford.com/forum/profil...wprofile&u=481 ) as he had that made for the set-up to his own spec.
Dan Cheers
MJC Well it was the inspiration from yours really. The fact that there is no need to cut any panels also helped
Still sourcing a few parts before it's all ready to be fitted, well the 8" fans really. Then a friend is making up the pipework and will be getting some Roose Motorsport hosing to finish it off. It may/ may not be done for the show season. Rather make sure I had all the right bits how I want them as opposed to doing a half-assed job just to get it in & running then redo them later.
Dan Cheers
MJC Well it was the inspiration from yours really. The fact that there is no need to cut any panels also helped
Still sourcing a few parts before it's all ready to be fitted, well the 8" fans really. Then a friend is making up the pipework and will be getting some Roose Motorsport hosing to finish it off. It may/ may not be done for the show season. Rather make sure I had all the right bits how I want them as opposed to doing a half-assed job just to get it in & running then redo them later.
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