Been looking for a intercooler for a while now, it was either £525 for a ss fmic and forge pipes or £600+ for a forge kit, far too much in my eyes so after a measure up and a night on ebay i came home to these

Also have loads of braided silicone connectors and elbows aswel, managed to get some time after work to get bumper, crashbar and any other plastic that was in the way off, and test fitted the fmic

Abit of chopping needs to be done and the top port is level with the crashbar leg so thatl need work aswel, hopefully get more done tomorrow night

Comments welcome

Edited 21 July, 201213 yr by x12_tag

How much is this way costing you for parts? . . . im finding it hard to justify the 600+ for the forge kit. . rather do the work myself if the saving is good enough. :-)

Under 200 so far, just need some clamps and thats about it

This could be very interesting!

Link to ebay for that FMIC?

As above linky and progress thread

Looks good

Jus look on ebay for a "twin pass intercooler" any intercooler should work it just makes it easyer with both ports at the same side, more progress tonight

well done for taking the initiative to build your own.. one thing i will say is that intercooler is far to big for that application. one little trick i learnt was to run small pipework to the intercooler and have a size reducer sleeve joiner thing which steps up the size just before the intercooler, this drops the pressure which also reduces the temp..

good luck with it, keep the pictures coming. :-)

I admit it is a tad big but im looking to get hybrid turbo next so itl soon come right, the fmic has 3" ports on it and im using 2.25" pipework to match the size of the egr delete im using, also planning to hard pipe all the ic pipes so less chance of leaks and do away with all the crappy oem pipes

on the engine side... ie the turbo outlet and the intake manifold/egr pipe you should use a hose with a hump in it otherwise the movement of the engine will pop the hoses off every 5 mins, youd be amazed how much the engine moves about under load/deceleration etc, these just allow a little bit of flex in the pipe

The cooler looks tiny on the bench but its massive on the car lol

The cooler looks tiny on the bench but its massive on the car lol

Yeah its a fair size, think the core is 300mm high by 450 wide and 3inch deep

What do u plan on doing about the crash bar?

Here my diy FMIC project, bought on a wim the other day on here from DIRTYDOG (i think thats his username lol)

just bought all the silicone pipework, bends etc, and i plan to run these with steel pipes between just to give a bit more flexibility to move the pipes round rather than having fixed corners. The intercooler looks slightly unorthadox but i like it and its different, plus it fits nice and low, just about sits on the bumper bottom on the inside, and fits snug between the crash bar and rad which is cool. Seems like it will get loads of air through the bottom grille under the plate, then the top of the rad is still open to lots of air through the top grille which isnt covered by the cooler which i have seen in others such as the seat sport one.

Nice intercooler mate

What do u plan on doing about the crash bar?

Im going to attack it with an angle grinder until.it waves a white flag and fits, ordered a map sensor port thismorning aswel

Hopefully ill get the fmic mounted tonight and start chopping the crash bar

Well done for thinking out the box.

Where are you putting the map plug?

Forge do them already mounted on pipework of your choice!

Itl b wherever the wiring will reach, yeah but i already have my pipework so ill just weld the port in when it arrives

How much did that sensor cost?

Just going to use my original sensor but the mount cost £22, think the sensors are £50

Not much progress today, made the 2 legs for the top bracket and welded it all up, more tomorrow

Saw this in carlisle the other day.. Parked up at the cross-roads near the petrol station. It looked good!

I'll be watching this for ideas!

How safe is it to cut the crash bar? I didn't really want to touch mine lol, mine literally just fits behind it. I have to cut the bit in the back of the bar, the one that looks like a box section, but that's it. I think I'm going to use the same sensor point that you have put up from awesome gti just hope the pipe work fits easy enough

Don't worry about cutting the crash bar, you could leave it off completely if you wanted to

Got some more work done tomade the top bracket fit properly, made the 2 tabs to mount the fmic, welded it all up and bolted it on

because of the way the bracket mounts on the legs where the bumper bolts onto i test fitted the bumper to make sure the fmic was in the right place, suprise suprise the bumper didnt fit so out came the grinder, had a quick measure up and got chopping, need to do abit more but its not far away

more tomorrow