W3STY's Progress Thread

[s3dave]

Yes i have 63mm, i meant to reduce them with the joiners...what outlets are they...

 

[superkarl]

I see what your saying, so the OD of the reducers or joiners will be too big, likely to be over 84mm.

 

[<tuffty/>]

Yes i have 63mm, i meant to reduce them with the joiners...what outlets are they...

Ah... yeah... IIRC they hit everything as std as they are higher up than mine on the AH... lower outlets (flush with the bottom of the FMIC) is the way to do it really...

<tuffty/>

 

[s3dave]

I see what your saying, so the OD of the reducers or joiners will be too big, likely to be over 84mm.

Yes thats right, like tufty says if they were alloy pipes coming off the FMIC @63mm then fine just enough room to play

 

[superkarl]

I await westys report on his night of frustration lol

 

[IrishDave]

I await westys report on his night of frustration lol

Yep same here. Have my finger on the refresh button awaiting some news.

 

[jk_s3]

*NEW* SQUARE Intercooler ~ Universal 460mmx300mmx76mm | eBay

hi guys, would this be any good? i know its narrow but the height is good, and also with the extra spaced saved by the narrow width would be good to get the reducers on before the fog lights?? its very similar dimensions to the forge intercooler, 20mm narrower but 30mm taller and 16mm thicker.

 

[Westy]

I'm just going to have a shower then I'll whack some pics up.

 

[Dani_B19]

Ooh you been getting down and dirty boyo haha.

 

[Dani_B19]

*NEW* SQUARE Intercooler ~ Universal 460mmx300mmx76mm | eBay

hi guys, would this be any good? i know its narrow but the height is good, and also with the extra spaced saved by the narrow width would be good to get the reducers on before the fog lights?? its very similar dimensions to the forge intercooler, 20mm narrower but 30mm taller and 16mm thicker.

Cores too small mate, its only 280mm.

 

[Westy]

Ok, I'm shattered after wrestling with that big *** core since 6:30

Anyway here's a few pics. First up, spot the difference:

Crash bar off, small core off, horns and middle bar off:

Lining up the big boy:

Drivers side pipework:

Passenger side pipework:

I didn't have the tools to cut the crash bar tonight so I mocked up a quick fix with some cable ties to hold the core up:

I tried my absolute hardest to get it to all fit but I could only get half the bumper on. The 90 degree reducers clear the fogs no problem, the issue is (as said above) the outer diameter of the silicone is too big to fit in the resess of the bumper.

Tomorrow i'll cut the crash bar, remove the fogs, raise the core and get it all to fit. There is a possibility that I can keep the fog trims but not sure yet.

Anyway this is how I left the old girl:

 

[Dani_B19]

So is it going to take some cutting of the bumper then? The fogs have 2 clips dont they, so couldnt you afford to cut/shave the bottom of the grille but still be able to use the top clip for the fog grilles to clip in! That make sense? haha.

Anyway neil, ****** good job, think im going to have to purchase one of these bad *** boys now.

 

[Westy]

So is it going to take some cutting of the bumper then? The fogs have 2 clips dont they, so couldnt you afford to cut/shave the bottom of the grille but still be able to use the top clip for the fog grilles to clip in! That make sense? haha.

Anyway neil, ****** good job, think im going to have to purchase one of these bad *** boys now.

There is a tiny possibility that the fogs can stay but the fog grills will need to be trimmed like a ****** or just left off. I'm hoping to have a bit more success tomorrow.

 

[Dani_B19]

Could you not pull the intercooler more in at the bottom, towards the car, or would it start fouling the top of the bumper/touch the rad?

 

[superkarl]

Is it that the silicone sticks out too much? Or its too tall from top to bottom to fit in the recess?

 

[Westy]

Could you not pull the intercooler more in at the bottom, towards the car, or would it start fouling the top of the bumper/touch the rad?

There's loads of room height wise but even with the core pressed right up against the rad, there is no room.

Is it that the silicone sticks out too much? Or its too tall from top to bottom to fit in the recess?

Yep spot on. The silicone is fouling the inside of the bumper where it's just too wide. Height wise the silicone will fit, just.

 

[badger5]

I may look at the feasability of modding this type for 63mm outlets welded on

 

[Dane]

Yep spot on. The silicone is fouling the inside of the bumper where it's just too wide. Height wise the silicone will fit, just.

But if it were all ally it might fit?

 

[Westy]

But if it were all ally it might fit?

Yeah it might do if the alloy was welded on. The problem with using a sili joiner then onto a 90 degree alloy is that the hoses then come out wider and foul the fog light brackets. The beauty with the 90 degree sili reducers is that the 90 degree bend is nice and tight.

If like Bill says you can get 63mm 90 degree alloy welded on I think it will fit.

 

[Dane]

Yeah it might do if the alloy was welded on. The problem with using a sili joiner then onto a 90 degree alloy is that the hoses then come out wider and foul the fog light brackets. The beauty with the 90 degree sili reducers is that the 90 degree bend is nice and tight.

If like Bill says you can get 63mm 90 degree alloy welded on I think it will fit.

Hmm I know just the man...

 

[Westy]

Hmm I know just the man...

Hopefully tonight I'll get it all fitted but I'm expecting to have black sili hoses poking out the fog holes. I cant be bothered with messing about getting welding done.

 

[Dane]

I can, mainly cus theres no messing about and its oooh 20 minutes away...

 

[Dane]

aww mate, I'm sorry

 

[Speedy Steve]

Hum this has got me thinking!

 

[Westy]

Hum this has got me thinking!

I think bigger is better. I dont care for the fogs any more, I just want my car running its best.

 

[Westy]

I'm picking up an angle grinder at lunch to do the crash bar tonight. Going to attack that fool.

 

[[Dave B]]

What about running a new S3 intercooler such as this one Audi S3 2 ltr T FSi intercooler and hoses New Genuine | eBay ?

It already has inwardly angled inlets and outlets? This has probably been tried and dismissed but I thought it was worth a punt....

 

[Speedy Steve]

Hum shame about the price

 

[Westy]

Not too sure without the measurements Dave.

 

[[Dave B]]

I'm struggling to find the height and width but so far I have found the following:

Core Width - S3 - 40mm
Inlet ID - S3 - 48mm

Quite a small inlet by all accounts but 270bhp S3's seem to cope with it? It looks like APR do an uprated one with 57mm inlets.

 

[badger5]

std S3 pipe is 60mm - I would'nt go smaller

 

[Westy]

Never fitted it in the end so no not got any pics for that... was too big for keeping fogs

Its plausible that knowing who and what I know now that I could have changed the ends and welded on 63mm pipes etc to allow it to stand a chance of fitting I guess... not sure what the actual size comparison would be but...

...vs my new AH one...

The ebay one being deeper of course... its possible it could be made to fit like my AH one with a bit of tactical fabrication...

<tuffty/>

Tufts, How did you fix the horns?

I've noticed there are a few screws sticking out already but have you any idea what size nut they take?

 

[Westy]

Forget my last post, this explains it

http://www.forgemotorsport.co.uk/media/S3FMIC.pdf

 

[Speedy Steve]

Yep thats where i put mine too although i plan to re work it all as want to fit my WMI tank in there to

 

[Westy]

Yep thats where i put mine too although i plan to re work it all as want to fit my WMI tank in there to

It was a tight fit on my setup to fit the horns there. I had to bend the bracket a bit.

If I got FMIC spray or WMI I'll be mounting mine where Dane mounted his, look very good, nice and hidden.

 

[Gti Jazz Blue]

......but ended up working in IT. That sounds familiar..... and I feel EXACTLY the same.

As I have a mate that is a mechanic and I'm in IT - I would say that IT is much better paid - unless you are someone like bill and set up yourself. General Mechanics aren't paid that well (when compare to IT).

 

[Dane]

It was a tight fit on my setup to fit the horns there. I had to bend the bracket a bit.

If I got FMIC spray or WMI I'll be mounting mine where Dane mounted his, look very good, nice and hidden.

I can take no credit, Tuffty's the man!

 

[Westy]

I can take no credit, Tuffty's the man!

I didn't think you had much to do with it

 

[Westy]

Bye bye fog lights

It's still not 100% how I want it but I'm too tired to give a **** right now. My old man is going to make up some brackets for me at work to further adjust the core height. This is how it is now.

 

[Prawn]

Nice man! Looks pretty mean.

If you're going to leave the grilles out, I'd raise the core up a tad so that the pipes are at least central in the appature.

Must be VERY good IATs with that monster core though. I must get myself one!

Any obvious increase in lag?