started to fit my intercooler this afternoon few issues but nothing huge and not finished yet but thought i would post my progress so far and start again in the morning. work was put on hold as i am going to make new brackets up to mount it as i dont like the box section mounts as basicly they are useless and possibly making up a new metal pipe that will get rid of another of the standard rubbish clips.

the start

removed the smic very easy to do

one pipe chopped

and another, this is the one i will replace tomorrow hopefully

finally maf pipe and sensor fitted

that is all for tonight

start of the second day. After i made new brackets up I had to disc some of the crash bar away, also ended up modifying the brackets I made aswell.

to start i had the old man take some aggression out on the grinder

this is the result

and with brackets fitted (ended up taking the welded nuts off as it was hanging to low).

the front mount fitted finally.

then onto the pipe work fitting and tightening.

maf all in place.

the one cut pipe.

the second lower cut pipe.

any cable ties about?

also had to relocate the horns from here after being moved once already (sorry no pics of the relocated horns)

then fully fitted.

and lowest pipe to the floor.

then back on the ground like nothing happened.

all in all its good for the price but it does take some bodging. I think if i gave this to a garage they would get half way and give up, but if your willing to make some of your own parts and hang on in there im sure anybody could fit it them self at home if your handy with a spanner and have a second pair of hands to help.

hope you all enjoy and apreciate the pictures as i know i few wanted to see what was involved, plus you might find it alot easier than me aswell.

did you have to unbolt the A/C and water rad to angle them for the cooler or did yours fit fine with the modification you done to the mounts?

Really put me off this intercooler :( think im gonna save up for the forge seat sport one! Just the fact u had to bodge to make it fit isnt the nicest thing in the world! Looks good on though mate!

No i didnt mess with the ac rad i didnt want to change all that so i ran the fmic at a slight angle with the brackets i made up.

If i had the money rich i would of bought the ths version idealy and got the guys at my local powerflow to make full custom pipe work up but all in would of cost me 2-300 more than this kit. Like i said this is very good for the money i didnt expect much more than i got after seeing other post but im. happy enough with the results

Really put me off this intercooler :( think im gonna save up for the forge seat sport one! Just the fact u had to bodge to make it fit isnt the nicest thing in the world! Looks good on though mate!

Thatb ne won't fit either, not without "bodging" a lot of the crash bar out of the way or using a SEAT Ibiza crash bar or... you get the picture...

Question for the OP...

If the intercooler was mounted the other way up (pipes at the bottom), do you feel that would improve the angle of the lowest pipe past the front frame? meaning it becomes less noticably low?

Not realy as th long pipe that runs along the back is as high as it can go so it will be the same either way. But if it was the other way i dont think the pipe work on the other side will line up correctly

Also o dont think it would fit behind the bumper very good atall the other way around.

I've done a similar fitment with a universal fmic.

The worst part was probably doing all this bogging then finding the forge vag connectors... So i purchased some more hoses and the connectors and then another eom pipe as I'd cut mine too and then bam. It's pretty good now. Wish I had known in the first place...

Oh and if your Alu pipes don't have lips on the ends then replace them with some that do.. Or some hoses with connector pipes as the pressure can pop them off! And at *insert high speed on motorway that may or may not be over 70* you're in trouble... It wasn't fun.

Thanks for a great topic with some good details.

Tom

Cheers tom. All the new ally pipes are flared its just the bottom oem pipe that i cut that isnt but i am getting a new flared one made up as soon as possible along with a new top section when i get a egr delete pipe.

Nice work joe, are you going to replace the pipe work from the turbo to the cooler at any point? The standard silicone on the turbo and pancake pipe are fairly restrictive and it's easy to replace you just need a 90 and 45 silicone bend and a length of pipe

Yes josh im getting the bottom pipe to the turbo replaced aswell as the top plastic pipe from the egr along with a delete pipe. Also want to do the elaphant mod to keep the new system as clean as possible

ive just got my intercooler and was thinking how to go about it but this has helped,ill go get me hammer,

Just seen this now, nice job!

Looks like quite abit of hastle mind. Any chance you could post up some prices and links?

Here you go hutchy http://www.txautosport.co.uk/seat-ibiza-19-tdi-lower-front-mount-intercooler-kit-335-p.asp if you ring them you should still be able to get the briskoda discount.

It wasnt to bad really, alot less hassle than my new system anyway.

How much discount did you's get?

Was pretty much everything needed included?

I read about you getting different pipes made up.

I cant remember not sure if it was 230.

Pretty much but they send box section for brackets as its ment for the ibiza and they fit in the crash bar ok but not in the fabias bar thats why i used the flat bar underneath.

I'm still tempted by one of these!

Ideal since mines an ibiza! Haha

Never thought of running pipes that way on the right hand side, mine has a very tight 180 degree bend then the long pipe goes along side and underneath the intercooler

I'm thinking of buying this kit and fitting it over the bank holiday, was the pipe that run on the underside okay? did you have to remove you under engine splash guard?

Did you witness any reduced temps and boost loss? was it worth it?

Cheers