Phil / Alex

If either of you fancy making a few quid it seems theres a fair bit of interest here (myself included) regarding the MAP sensor mount.

Alex - Would you be interested in making up some stainless pipework aswell?

Cheers for the info guys

I have nearly finished mine, and have made a complete spare pipework kit too, including EGR replacement pipe etc. Will post up some pics and more soon, once it has been trial fitted etc

Alex

Hi guys,

for those of you who asked - here is the latest version of the map mount. I've updated the design since doing mine as the wall thickness on the neck was a bit thin so there was a bit of pentration with the weld which meant I had to run a drill bit down the hole before fitting the map sensor and the over-hang was too much so they couldn't get the head of the welder in there.

Will try and find some time this evening to put the rest of the pics etc up.

map_mount.pdf

why use an expensive ebay intercooler?? there are lots of intercoolers than will fit kocking about in breakers yards, i did one for a mate a while back using a mercedez sprinter intercooler and it cost about £50 all in

They're quite good value for money plus the pipe work is at the right end but if you can source a suitable second hand one then all the better. The only problem you might find is alot of the OEM intercoolers have an aluminium core with plastic end tanks, they are crimped together with aluminium 'fingers' that are formed over the plastic tanks. The problem you have is if you put any resonable amount of boost through them the fingers start to spread and they leak. Renault 5 turbo's used to suffer from it, and to over come it they'd strap it up with a couple of huge jubilee clips!! lol.

why use an expensive ebay intercooler?? there are lots of intercoolers than will fit kocking about in breakers yards, i did one for a mate a while back using a mercedez sprinter intercooler and it cost about £50 all in

These intercoolers are hardly expensive when compared to the likes of Forge or Pro Alloy. I am looking at about 200 quid all fitted.

Alex

The good thing if you do find an OEM one in a scrappy that will do the job is that the tend to be much thinner so will probably sit behind the bumper bar without the bar needing modification. The only down side is I can't see them being as efficient.

Right guys - here it is. Sorry it's been a bit slow coming - i've been flat out in work the past few weeks, starting work at half 5 in the morning just to try and get the work done.

Anyway. Here we go.

Taken note of where the intercooler is positioned. It needs to be across to one side to make room for the pipework so it can clear the bumper bar. The 'meccano' comes with the intercooler. I just bent the ends over to make a small L so it can be bolted to the top of the intercooler and then to the front panel.

The top pipe is connected to the intercooler using a 3" to 2.5" 45degree joiner and the bottom one is connected using a straight version.

Here you can see the pipework a little better. Starting from the turbo, we have the original rubber 90degree bend. I have then fitted a 2" to 2.5" joiner which then attaches the first 90degree bent aluminium tube. A straight 2.5" joiner joins this to another 90degee bend which goes into the bottom of the intercooler. The top pipe is a 45degree bend. This joins to a 60degree bend using a 2.5" 90degree joiner. The last pipe you can see at the top of the pic that goes up under the front panel is a 45degree joiner. behind where the two pipes come together before going into the intercooler the is a rib running down the front panel - you need to break this off to clear it. Also you need to run the pipework as close to the chassis leg as you can otherwise you won't get the bumper back on.

Here is the bottom pipe meeting the turbo.

This isn't a great picture but it shows you where I have mounted the map sensor. I've tried to mount is as close to where it would have been original as possible so that there is no need to modify the wiring.

Here is another pic - there is a small tab of metal on the inner wing that needs to be bent a little to help the pipework to clear the back of the headlight.

Here is the other end of that pipe with the map sensor fitted into it. It joins onto the original bend using a straight 2.5" joiner.

The bumper bar needs to be cut in the two places shown.

Hear I cut through the bumper bar and then drilled out the spotwelds to remove the inner skin of the bumper bar and then folded the metal inwards. This is strong stuff so it will take some time. This is to clear the pipework coming out of the intercooler.

At the opposite end i've cut a groove through the middle of a 'lump' in the bumper bar and flattened it out with a hammer. This is to help clear the end tank of the intercooler.

Here is the bumper bar re-fitted. It's a really tight fit and holds the intercooler snuggly so i've not made any more brackets to hold the intercooler in place - it ain't going anywhere!! lol.

As you can see it's well tight!

The only other thing I had to do was bend the brackets of the horns to clear the end tank of the intercooler and the back of the spot light on the front bumper. There is another modification that I forgot to take a pic of, this is inside the front bumper on the drivers side. There is a piece of plastic near to where the spot light sits, the spot light doesn't bolt to it - that needs to be trimmed off.

Just to warn you guys - this isn't something you'll do in an afternoon so don't blame me if your without your only car after attempting this on a Wednesday night. You'll need to get all the components, get a hacksaw out and get trimming the alloy pipes bit at a time until your happy with the fitting. The strip it all off and get ribs welded around the ends of each pipe. Also drill a 12mm hole for the map sensor mount and get that welded on the same time. Make sure you clean out all the pipework when you get it back to get any swarf etc out of it before fitting.

good work, that's a nice tidy install

Cheers. It came out better than I was expecting to be honest. After buying the intercooler I didn't think it would be as straight forward as it was.

looks a good "easy" job Well done mate

Looks great mate, job well done, are you goin to be doin an open mouth front grill?

Any photos with the bumper on?

Looks good mate. Will be good to see it with the bumper on! Looks a good job.

This is my Map sensor mount, shaped perfectly to the map sensor, with location pins and M5 threads to take button head bolts. I have made a couple so when the kit is complete, will more than likely have a complete kit for sale

Alex

Alex - how long is the neck on yours mate??

I've had a couple of PM's about a shopping list for this kit.

Your going to need,

1) EBay intercooler - check the size, make sure it's not bigger than the one in this link,

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=320282898740

2) EBay universal pipework kit - 2.5" type. Now this comes with injection moulded silicone bends. I didn't like them so opted to buy some standard 'wrapped' versions.

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=250354931202

3) EBay silicone bends and joiners. The cheapest I could find is this place :

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=120360780775

In total I needed :

1 x 3" - 2.5" straight reducer

1 x 2.5" - 2" straight reducer

1 x 3" - 2.5" 45degree bent reducer

2 x 2.5" straight joiners

1 x 2.5" 90degree bend

4) Map sensor mount - a local machine shop should be able to make you one of these quite easily.

5) Someone with the ability to aluminium weld!

Edited 5 March, 200917 yr by TokyoPhil

I have used this smaller intercooler, available from the same place and this DOES NOT require any cutting of the bumper bar etc to fit. I will post some pictures up next week.

They say the intercooler is good for 400BHP and I calculated sizes, volumes etc and the smaller cooler, 300mm x 280mm x 75mm core size is as big as i really wanted to go. Volume wise it works out more than that of the Seatsport and Jabba ones (if my calcs are correct) AND it fits easily!

I have then used 2" pipework to match up the orignal pipework, again gives you that bit more space around the engine/bumper without being restrictive.

Hope this helps

Alex

Alex - how long is the neck on yours mate??

Part is 20mm from where the sensor bolts on, but once profiled with the 2" to suit my pipework, gives about 16mm at the shortest point. I have a 18mm bore to suit the map sensor which will be put through the pipework too once welded.

Alex

That might be a bit on the long side mate - try your map sensor in it before you weld it on. You want the portion with the holes cut through it to be hanging in the air flow otherwise it won't pick up temperature (as it's a 4 wire sensor it reads charge temp as well as pressure).

I just went for the biggest intercooler I could make fit!! lol.

I have it sat on my desk with a map sensor in it. It will end up exactly as it sits in a std intercooler.

Alex