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Thread: Fitment of FMIC, 76mm outlets, retain fogs.. reducer?

  1. #1
    ToonRing-G's Avatar
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    Fitment of FMIC, 76mm outlets, retain fogs.. reducer?

    Hi folks, I have a 600x300x76mm Intercooler I got fairly cheap, and I'm looking to retain my fogs when I fit it, ive read over the large intercooler page and seen the various fitting methods and concluded that its going to be impossible to get 76mm hoses and keep the fogs, the only option is losing them.

    However, my question is, could I use a reducer down to say.. 60mm? and retain them that way? would there be enough space behind the bumper to have a 76mm-60mm reducer hose and keep my fogs?

    The only other option I can see is selling this FMIC and getting another one with smaller outlets, and id really rather avoid it!

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  3. #2
    superkarl's Avatar
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    You haven't read the FMIC thread hard enough.
    All your options are included in that, including retaining fogs with reducers

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    ToonRing-G's Avatar
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    a link to the specific page would be nice. nonetheless, its exactly the response I expected to get.

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    Check the stickies section.
    AH Fab / Ebay / Forge S3/A3 FMIC installs (image heavy)
    You will find all known available info in that thread.
    B5 v1 Tip, Relentless v2 Manifold, Beach Buggy Hybrid, Pipewerx D.P and cat bypass, Miltek resonated cat back, AH Fabs v2 Intercooler, S2000 Filter, 83mm 9.5:1 CP Pistons, Brute Rods, Bosch 550cc Injectors, Oil Catch can, N249 delete, B5 Phenolic Gasket.
    H&R Springs, Koni FSD Shocks, s3dave's rear tie bars, LCR Brembo's, 18" ttrs alloys, replaced all suspension bushes, 15/20mm spacers front/rear.

    Now just waiting on my B5 exhaust manifold as the Relentless is goosed.

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    ToonRing-G's Avatar
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    with all due respect guys, that thread is now 20-odd pages long and thus far, all I have found out is that it cant be done (westy used 90 degree 76-63mm joiners and couldn't retain fogs, well, couldn't keep the grilles) so I still cant see where the keeping fogs with reducers option is..

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    superkarl's Avatar
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    You just answered your own query, westy kept the fogs. Not the grills.
    It was fogs that you said you wanted to keep.

    Essentially, to sum that thread up, if you're using a 300x600x76 core, you need welded outlets in order to keep fogs AND grills.
    Dani claims he did it with reducers, but I don't think anyone has seen his car and hes been a member since he was a featus.
    Dani_B19 and s3dave like this.

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    Lmfao @ karl. Paul, avlo and shaun have all seen my car and can vouch for the cooler lol, but yes I have fitted the wellycooler with 76-63mm reducers and kept the fogs, id dare say id be able todo it all in 76mm if needed but it isnt.
    Driving the most secretive S3 on ASN

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    Slightly off topic but does the fmic need to be so big? Ive found an fmic with the dimensions recommended but with 63mm outlets. Saves reducing?

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    I'm fitting the same fmic (welly cooler) well the same as Karl . Welding 63mm 90deg bends on and basically following the man of steels thread . Everything you need is in his thread . A question too Karl did you cut the bends down before welding them and is it worth pointing one down a bit and off setting them in the cooler . So I don't have to bend that bracket and so I don't have to cut as much away . I'm going to weld them myself so I'm open to suggestions .

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    Who needs fogs,shout about it I reckon ImageUploadedByTapatalk1388400062.388764.jpg
    Using Tapatalk

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    Tom what coolers that? Also what size is the pipework?
    Driving the most secretive S3 on ASN

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    Quote Originally Posted by ToonRing-G View Post

    The only other option I can see is selling this FMIC and getting another one with smaller outlets, and id really rather avoid it!
    There is a cooler out there with 600x300x76 dimensions and with 2.5" outlets. PM me if you want more info on where to buy it from as I don't think there available on ebay AFAIK.

    I'm still waiting for mine in the post

    Chris
    2000 S3 APY

    18" BBS RSII with Michelin PS3s, 20mm H&R adapters, Relentless 3" DP and Sports cat, B5 V1 induction kit, cone filter+heat shield, Forge 007P, Awesome GTI SMF, AP coilovers, Facelift rear lights, Full Powerflex poly bush kit, R32 Rear ARB, SAI delete, N249 by-pass, Upgraded Engine mounts with Polytek, Stage 1 CC at Badger 5.

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    Why do you need 3inch pipe work?

    63mm will support more than most need,
    500bhp easy.

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    You dont. Its just most coolers of that size have 3 inch outlets so you reduce down after.

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    Quote Originally Posted by audiholic ste View Post
    I'm fitting the same fmic (welly cooler) well the same as Karl . Welding 63mm 90deg bends on and basically following the man of steels thread . Everything you need is in his thread . A question too Karl did you cut the bends down before welding them and is it worth pointing one down a bit and off setting them in the cooler . So I don't have to bend that bracket and so I don't have to cut as much away . I'm going to weld them myself so I'm open to suggestions .
    I didn't cut the bends no. Il get some measurements for you as soon I can

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    Quote Originally Posted by Dani_B19 View Post
    Tom what coolers that? Also what size is the pipework?
    Universal intercoolers but the kit is for an S3,it's spot on pipe work is 51mm to 60mm,find them on fb
    Using Tapatalk

  18. #17
    audiholic ste's Avatar
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    Cheers pal . I read in another post of yours that you would like to learn to weld . I've been welding for 20 years stick gas mig and tig welding if you ever want a few lessons I would be happy to help . Got loads of scrap you could play with .
    Dani_B19 and superkarl like this.

  19. #18
    superkarl's Avatar
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    Quote Originally Posted by daz-20vt View Post
    Slightly off topic but does the fmic need to be so big? Ive found an fmic with the dimensions recommended but with 63mm outlets. Saves reducing?
    this would be perfect!

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    Quote Originally Posted by daz-20vt View Post
    You dont. Its just most coolers of that size have 3 inch outlets so you reduce down after.
    Sorry I actually miss read a few posts lol!

    I'm going to be looking for a cooler shortly, originally I was going to go for the ah one, I probably still will, but I'll be looking to see what's out there as well,

    If you know some one with the tig gear can always cut the outlets off and weld on 63mm outlets.

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    Im in the annoying situation i cant change to an fmic until my insurance ie due for renewal. Admiral dont cover them. Ill see if i can source a link for the fmic i saw

  22. #21
    superkarl's Avatar
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    The thing with using silicone on the outlets of a core, 63 or 76, is that the silicone is a good 3-4mm thick.
    It will never be as good a solution as welded on pipework like the AH or like some of us have done with the wellycooler.

  23. #22
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    [IMG][/IMG]

    [IMG][/IMG]

    Thats with reducers.. The best i could get it!
    Quote Originally Posted by <tuffty/> View Post
    its either mapped or broken...

  24. #23
    superkarl's Avatar
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    Ahhh yes, I remember complimenting you on a good job at inters G!
    Gops likes this.

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    Thanks Karl! I remember that sunburnt day! Next year im bringing sun cream, you can rub it on my back lol
    Quote Originally Posted by <tuffty/> View Post
    its either mapped or broken...

  26. #25
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    You can sod off! Lol

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    hahahaha! im going on the strip next year! But back to the thread.. I had to trim the grilles abit to make it fit as much!
    Quote Originally Posted by <tuffty/> View Post
    its either mapped or broken...

  28. #27
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    I got my 90's welded on to my welly and kept the fogs, grilles and everything looking oem. It was really really easy. However much I'd like to claim genius status for this I ruthlessly stole it from Karl's thread, cheers Karl
    Badger 5 tuned 340 bhp / 350 lbft sleeper

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    My last s3 i had in 2005 had a universal cooler. Was a 550x280x65 core with 63 outlets. This made me able to fit silicone joiners to the cooler instead of silicone 90's. Then i used an alloy 45 (i believe) like karl says the outside diameter of alloy is much less than the silicone. I kept my fogs and all grills (grills needed sanding the back off a touch) but it looked completely oem. But from what i research now most would say that the cooler i used was too small. A mate logged the car and he was impressed with all the results. Any thoughts?

  30. #29
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    Quote Originally Posted by superkarl View Post
    this would be perfect!
    Our good friend mr Beach Buggy now sells just that karl!

    BBT now sell a cooler which uses the same core and end tanks as the welly cooler, 600x300x76, but with 63mm inlet and outlets

    Perfect for anyone wanting to save vital space retaining fogs and grills, and works out at a similar cost to buying the wellycooler core and reducers anyway, so it's a no brainer for anyone concerned about looks.

    You all know where to find him too search beachbuggyturbos on facebook
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  31. #30
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    thanks guys, just shows that a bargain aint really a bargain if its going to turn into a complete ball-ache to get the fit I want! so either I'm getting pipes welded on, or the FMIC is getting sold on and i'll just have to get another one! baws!

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    Is bbt only on facebook? Im not on it as its the root of all evil. I found one overall sizes 790x300x75 with 63mm outlets under a ton. But would favor something tested.

  33. #32
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    Dan isn't just on facebook no mate, he's also on here as BeachBuggy, or if you have no joy drop me a PM and I'll sort you out an e-mail address and phone number
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    audiholic ste's Avatar
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    Karl if you could have a look and see what size pipes you used I know there where 63mm o/d but what length where they . Might get a week off soon and try and get a shed load of work done to the car .

  35. #34
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    Needs to be 930mm gap internally so the 90 degree hard pipes need cutting down yes and point them down slightly then you miss a bracket

  36. #35
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    I am following Vrbobs FMIC build currently, which is allowing me to keep my fogs and grills. Heres a link

    FMIC fitted :)
    2001 Audi S3 8L Ming Blue - LOST THE ROD LOTTERY BIG TIME (Rebuild underway)


  37. #36
    audiholic ste's Avatar
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    So is that 930mm between the pipes or the center of the pipes cheers Steve

  38. #37
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    Between the pipes O<.........930.........>O
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