fiestaturbo.com

[Stoned]

Right I'm pleased to say I have finished converting my car to a cossie intercooler and I'm gonna show you how I did it

And then you can just look at pics and admire the car

First of all I would like to say thanks to Moondust FRST. Without seeing a pic of his GRS IC pic I would never have got my idea in the first place. Cheers dude

Second my aim was to increase the cooling and IC performance by getting bigger items, but without messing up the looks of my car. I think what I have done is a good blend of looks and styling, but let me know what you all think too.

The project conception, some crap scrawls on a bit of notepaper


Then the design that poor Graham at GRS had to work with lol. Aint windows paint a quality app?


More


The finished product back from GRS. Amazing considering what I gave him to work with haha


Next I had to get my car like moondusts. The reason being when you remove the front valence I noticed on his car a small lip of metal that I quickly realised could be used to weld a shelf too. So off with my bumper and valence


Rough cut, but you can see the metal lip I was talking about


Now a quick test to see how my cossie intercooler would fit


Next fast forward a few weeks and I have had my shelf welded into place and I have spray painted it


And here is the IC and rad in place. Unfortunetly my measurements for Graham were out so I sent the stuff back to him afterwards and he sorted them all out for me


And here are the pics of the finished result of my work. Tooks months to come to this which is why I am sharing it with you. Hopefully you might get some idea's of your own from it



Look at all that room! No fan getting in the way


New layout


Rear mounted XR2i fan. Having an XR2i shell worked in my favour. The mounting wholes were already there so only an hours extra work cutting and drilling was needed to get that in place


Overhead view




Obviously the number plate get's in the way a bit, but I dont mind as I wanted the new IC to be stealth anyhow. I can always remove the plate for track runs anyhow.


Beast


So what do you all reckon?

[chumkila]

Blinding mate. Whats the decrease on ACT's?

Looks like a fab piece of kit.

[Poom]

Im spent....

[TJ]

Thats a top fukkin job indeed!

I love it"

[Stoned]

Cool, I'm glad you like it

Chum: I dont know because I dont have an ACT gauge yet. It's on my xmas list

But there is defo more power than before so the temps must be quite a bit lower. It's a 4x4 cossie intercooler so probably overkill, but lag is not increased and defo more power.

After reading Ade's article on improving power on turbocharged Fiesta's I wanted to get the best from my current 10psi before having it mapped for 15psi. And I decided getting an uber cooler would be the best way to do it.

[GavStyli]

Very very nice Chris
all the hard work, ups and downs have paid off in the end
let us know your ACTs now, should be much much better than the pace interwarmer.
you defo need a smaller number plate to get the better airflow to it.

[andymac]

Lovely bit of work there mate.

[housey]

Beeeeeeauty !!!!

[Asad]

you defo need a smaller number plate to get the better airflow to it.

Agree with that!

Looks nice but you need to move the plate. how about onto the bottom lip of the spoiler?


Asad

[Stoned]

mmm I dont really like plates on there. Moondust's looks alright because it's tiny. But Plod dont like those plates and I dont want trouble from them.

[Fezzy Turbo]

Brilliant!

Bet that works better than any Pace item

Agree with Gav, you need lift your number plate for better airflow.

[AndyKam]

Nice one mate. Looks well sweet. let us know how the car feels with it on.

[1600power]

supurb m8, looks the dogs and i gotta agree with ur stealth comments!!! thats the way to do it

[AndyBlackFRST]

Looks sweet mate, was wondering why u didn't put the fan on them front of the rad though

[Stoned]

Because it didnt fit with a tube either side and the strut in the middle. It's simply too wide.

Rear mounted fan keeps things clean and appears to be up to the job

[AndyBlackFRST]

could you have gone for 2 smaller fans on front to force the air through?

[Stoned]

I dunno. As you know FRST's run rather hot and no one seemed to think kenlow fans were up to the job, They would only be about 8" wide and that's really too slow to be effective

Besides I think it looks better this way and it works well. And the XR2i fan only cost me £20 inc P&P (cheers Bezo!)

[AdrianFRST]

Top work!

Very neat and looks good too. The perfect solution for your car!

Typical response over on passioncosworth I see...

[Stoned]

Glad you like it Adrian.

I have been mulling over the airflow problem and may just move the number plate up to cover that small vent.

It means less air to the rad, but more to the IC
swings and roundabouts...

[Red16]

well done that man, absolutely pukka job there, looks awesome

[AndyKam]

Why dont you fit the number plate on your splitter like Sunny has?

[img]http://www.fiestaturbo.com/phpBB/gallery/andykamren[1].jpg[/img]

[Stoned]

Because it looks a bit naff.

Sunny's is more of a track car so it doesnt matter, but I want mine to look as close as possible to how it's always looked.

[AndyKam]

Sunny's is more of a track car so it doesnt matter, but I want mine to look as close as possible to how it's always looked.

Fair point. Just a thought though.

[Stoned]

Don’t take that wrong. I appreciate the suggestions and advice, I just thought of that early and did a quick Photoshop and decided it wouldn’t look right.

Moving the number plate up is fine, I'm just a little concerned that it would block what is otherwise a source of air for the radiator

[Brycey]

What about a small plate like Paul R?



So it'd look like this...

[Stoned]

It is an option, but Plod wont like it and that will give them an excuse to pull me over and nitpick on things like my tinted lights and the future flamer kit

It depends if I can get a compromise, something smaller without being blatently illegal. Probably taking the silver trim off will reduce the plate size by a good few milimetres on it's own

[InS@nE]

very nice indeed matey, i fitted a twin 2wd cooler set up on my old orion and was runnin sooooo much better was getting inlets of like 7deg on really cold nights.

as for the covering up issues, surly moving the plate up wont affect temps as you have the massive grill area to cool it down and rad is quite high up any way aint it. you'll get better inlets as cooler will be getting greater airflow

thats whay mine was like

[MOONDUST FRST]

Looks good mate, I wouldnt fit a small plate though as i did that and got erm fined etc. You could trim the original down around the edges a little though and raise it just a tad higher
Top job
Oh nice cooler on that black orion mark

[dannyboy]

Looks very nice and original Stoned. I don't think the smaller plate would look out of place and won't atract the cops any more than your car already does, if they are driving behind you they cannot see the plate but can see the tinted lights. Most cops arn't to bad, once they realise you are not just a stupid boy racer they relax a bit, IMO anyway.

Dan

[elm_us]

very nice mate,

hope ya cleaned it up behind ya bumper

[InS@nE]

Oh nice cooler on that black orion mark

[Project]

How about the room behind the cooler - doesn't look like there's any room at all for any airflow behind it...?

[AndyRS1800]

As you say you are open to suggestions...

Get rid of the chrome maxpower cheapness numberplate surround, cut plate down a tiny bit... sorted...

Sorry its just your numberplate looks to big and maxpowerish...

[Stoned]

elm: Not yet. I'm taking the bumper off again at the weekend, at which point I'll give it a careful clean and polish as there is a small rust patch around each hole for the bumper.

Project: There is actually some room, I couldnt put it compleatly flush against the back as the strut is in the way so airflow should be fine.

Andy: I've always rather liked that 'max power' silver trim

But I shall remove it anyhow and shave the plate down on both top and bottom to thin it out a little. Then I'll move it up 10mm or so and that should sort the problem.

Roll on the weekend!

[chumkila]

I say keep the plate where it is Stoned.