My BAM Repairs and Mods

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imz

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Hi all I bought a Wellycooler from a fellow member which my mechanic is attempting to install for me.

He’s struggling to retain the fog lights which I really would like to keep. I checked with the seller and was told he kept them when he had it mounted it to the car.

My mechanic has said the fog grills are now not going on as the 90 degree silicon bends (63mm) are pushing through the grills.

Can anyone please advise if there is a solution round this so I can retain my fogs such as pull the bottom of the intercooler further back, lift it higher up or drop it further down please?

Thanks


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it's frustrating isn't it - I needed to shave my fog grills, trim the inside of the bumper and get the intercooler pipes in as tight as possible especially on the drivers side, I recall not returning the bumper back to the original lower mount holes too, maybe out 5-10mm. If someone can weld your can weld the 90 degree hard pipes directly onto the welly cooler.

some people have fitted them upside down but that is a chore for sure, getting around the crash bar.

it'll work out I am sure :)
 
How have you got the core mounted? Is it possible that the previous owner had the core further back than your mechanic is attempting to fit it?
 
I’m popping down in the morning to take a look at what he’s done but basically these are the images he’s sent which looking at I wouldn’t think the fogs would be affected, thoughts?

Apologies it’s not the most useful pic, I’m actually hoping he’s not relocated the horn and that’s the issue.

de44b27b4f077e3020cbbd171de528d8.jpg



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I got a fmic fitted and my mechanic that did it told me it was a nitemare to do.
He had to trim the bumper so it would go on he also had to trim the fog light surrounds and also lost one fog light mounting bracket of each side to get all mine back together. Mine was a airtec not a wellycooler but could be same thing to try.
 
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the horn is on a bracket above the crashbar, you might think you are surprised the fogs are involved but they are.

but if he has managed to the bumper on keeping the fogs and the bends then it's just an extra trim here and there - but it does take hours of faffing on, I tried a mixture of different arrangements, it even got down to the angle the JBS clip adjuster was at.

I assume all of the metal pipework has flanges, otherwise the hoses will just pop off over about 10psi.
 
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Looks too small to be a welly cooler... normally the end tanks aren't visible in the centre section of the grille.

<tuffty/>
 
This is the IC I was told by seller on here it’s a Wellycooler though would appreciate knowing either way please?

Wish I’d have bought an AH v2 now, guess we live and learn.

da669977caf470cf5a541d3295afcfc1.jpg



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A 'welly cooler' is a toyosport type B which has a 600x300x76mm core
https://www.toyosports.co.uk/fmic-ffront-mount-turbo-intercooler-type-r-550x225x64mm-7499-955-p.asp

That one looks to be a type R
https://www.toyosports.co.uk/fmic-ffront-mount-turbo-intercooler-type-r-550x225x64mm-7499-955-p.asp

Arguably should be easier to fit... to retain the fogs you need to get the pipework as low as possible... there was a reason I designed the AH v2 the way I did... with the 63mm 90 degree outlets and low down it tuck into the lower part of the bumper... bit trickier on the 'welly coolers' as the outlets don't sit flush to the bottom of the end tanks

<tuffty/>
 
imz said:
This is the IC I was told by seller on here it’s a Wellycooler though would appreciate knowing either way please?

Wish I’d have bought an AH v2 now, guess we live and learn.

da669977caf470cf5a541d3295afcfc1.jpg



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Click to expand...

That should fit in an S3 keeping the fog lights and grills. It'll just take multiple attempts to get pipework sorted, and you find you trim off some bits just to move the bumper in 10mm closer then repeat the process.
 
Thanks for all the help guys really appreciate it will keep you updated this morning once I get down there (haven’t slept most the night ended up reading the entire sticky and also a thread by vrbob where he got a welly cooler in and also retained his fogs)

As a side note given the dimensions of the cooler should I be looking to mount as low as possible then as you mentioned Tuffty or does the fact that it’s smaller change this?

Thanks


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Don’t be afraid to trim your bumper, fogs and grills. Just do it little by little, a piece at a time. Trick is not to take so much off the grills will no longer clip in and the fogs aren’t hanging on with anything. I did mine couple weeks ago, arguably that intercooler you’ve bought looks smaller to the Airtec, but only slightly. Shouldn’t be too difficult to fit. Like Tuffty mentioned, keep it as low down as possible.
 
The bottom of the intercooler essentially matches the bottom of everything else. It'll fit you just need to be patient, which I know is frustrating when paying someone by the hour.
 
Hi all still struggling. Wish I’d done my research properly like I did with the down pipe and got it from pipewerx.

Anyhow does Bill still do the modified FMIC? Also does it come with all the pipe work and hoses?

Thanks


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imz said:
Hi all still struggling. Wish I’d done my research properly like I did with the down pipe and got it from pipewerx.

Anyhow does Bill still do the modified FMIC? Also does it come with all the pipe work and hoses?

Thanks


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Click to expand...

Morning bud, you won’t be able to buy the intercooler modified from bill and fit it yourself. He would need your car so he can measure and weld to fit. You still struggling with getting the bumper back on? Or retaining fogs, etc.


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Thanks for getting back to me buddy.

Out of interest where is Bill located as I’m looking to do an engine rebuild in the next year or so and would only want Bill to do it ideally.

As for the current problem, they are getting the silicon pipe too close to the fogs and so under boost the fogs or the plastic surround will pop off as the pipe expands.

I’m wondering if I just get them to weld metal pipe coming out of the Intercooler and round the side then there’s no issue?

They’re suggesting putting the Intercooler upside down, but if a pipe pops off I’ll be stuck with no choice but taking the whole bumper off. The thought of which on a cold winters night scares me


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Haha, that thought scares me too! I had to remove one corner bracket off the fogs, they still hold on fine and lots of trimming on the grills and lower part of the bumper to fit mine, even then the bumper was a squeeze to get on. The silicone pipes on mine are squashed “slightly” nothing to worry about though. Just make sure your hard pipes are all beaded ends and you use decent JCS High Grip stainless steel jubilee clips, do these up tight and you should be all good! If your mechanics can cut and weld tighter elbows off the intercooler so you miss the fogs then brilliant, Tuffty and others had done this to there’s. Bills is by far the nicest set up having the intercooler upside down, etc.


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Have they shaved the fog grills, my driver side for grill was down to about 1mm in one place? They could probably create a retaining bracket, to pull the piping back, but maybe they have fitted it squashing the silicon pipe. I was scared of them popping the grills off too, so put a tie wrap round the pipe and grill. I was considering cutting off the towing threaded tube or some of the plastic surround on the drivers side.

I saw some pictures of an intercooler being fitted by badger5 to a TT the other day, it's an expensive service (probably not if you are paying per hour for yours) but the fitment to the crash bar by welding on new brackets and the custom hard pipes is inspiring.


https://www.ttforum.co.uk/forum/viewtopic.php?f=2&t=1848623&start=105

There's really a difference between an expert at something and a chancer...
 
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Stuart B said:
Have they shaved the fog grills, my driver side for grill was down to about 1mm in one place? They could probably create a retaining bracket, to pull the piping back, but maybe they have fitted it squashing the silicon pipe. I was scared of them popping the grills off too, so put a tie wrap round the pipe and grill. I was considering cutting off the towing threaded tube or some of the plastic surround on the drivers side.

I saw some pictures of an intercooler being fitted by badger5 to a TT the other day, it's an expensive service (probably not if you are paying per hour for yours) but the fitment to the crash bar by welding on new brackets and the custom hard pipes is inspiring.


https://www.ttforum.co.uk/forum/viewtopic.php?f=2&t=1848623&start=105

There's really a difference between an expert at something and a chancer...
Click to expand...
Bills definitely got skills. Can’t wait to bring my car to him, looking like beginning of next year now at the rate I’m going
 
Just gets better.

So they’ve completely chopped the crash bar rather than trim it so I would rather get another crash bar and get them to do it properly.

Does anyone know if the a3 front crash bar is the same as a s3?

They’ll be starting again tomorrow so would want to get it in ASAP.


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I cut my crash bar to the maximum I could so I could still mount my intercooler, Airtec suggested only “trimming” enough to fit the intercooler in. So I cut loads basically, my thought was to allow as much air around the intercooler as possible.As long as you can still use it to mount the intercooler then you’ll be fine mate. The crash bar is fairly useless in terms of a “crash” it’s there for very minor bumps to protect rads, etc. Your intercooler has top and bottom mounts doesn’t it? As long as they’ve not cut completely through the crash bar I.e. the two ends aren’t connected, then you’ll be fine.


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It’s basically in three pieces the two sides about 40cm are still there but the whole middle section has been chopped out.

They’ve then rotated the sides completely back towards the rad so basically there’s no crash bar where it was originally.

Does that make sense?


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Ah okay, I see what your saying..... far from ideal! You could mount the intercooler at the bottom with a couple of brackets, then the two 40cm ends of the crash bar, I’d make up a metal “bridge” which would go from one end to the other, but over the top of the intercooler and attach the intercooler to that as well. Without drawing a picture it’s hard to explain. Haha.


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Something like this, not to scale and a bit rushed, but you get the idea.

8d95016364d6e6e1cb442574ef638eb9.jpg



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I think all front mounts other than a Wagner you have to cut trim and also the crash bar, there simply isn’t enough space.
 
Awesome will tell them to mount something over the top as per your pic. Thanks for taking time out and all your ongoing help


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imz said:
Awesome will tell them to mount something over the top as per your pic. Thanks for taking time out and all your ongoing help


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Click to expand...

Your welcome buddy, anything is possible. Just make sure they mount the intercooler as low as possible like others have said, this will allow the maximum clearance for the pipework. There will still be some trimming needed for the bumper and grills, just little by little, to much and you could end up without grills and fogs.


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Is it worth getting the metal pipe welded on as that would gain more than enough clearance if I’m correct?


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imz said:
Is it worth getting the metal pipe welded on as that would gain more than enough clearance if I’m correct?


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If your confident they can do a good job welding it on, then yes. Would save a lot of trimming.


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The TT had a different crash bar, with s3 I needed to cut two small triangles though.

This has become a bit of a chore, hasn't it.
 
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its got to be the trickiest, none straight forward thing I've had to do on the car so far..... not looking forward to fitting a pipewerx 3" downpipe. I might be cheeky and get Bill to fit it when he does the rest once I've done all that I can do.
 
Ive had the pipewerx fitted as part of the work just haven’t been able to hear it as the car has no Intercooler or pipes

Does it make a big difference in terms of sound (I opted for the decat)?


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Lol I fitted my 3 inch downpipe today :D :D it's a small reward for a 2.5k mistake

Although I did cut the hanger off when I fitted it the first time.

Screenshot 20180902 202715 Gallery
 
Stuart B said:
Lol I fitted my 3 inch downpipe today :D :D it's a small reward for a 2.5k mistake

Although I did cut the hanger off when I fitted it the first time.

View attachment 164377
Click to expand...

Hey Stuart, was fitting the downpipe way easier with the head off? I know it probably should be, but you’ve got hands on experience now this is why I’m thinking I’ll let Bill do mine being as the head will be off when he’s got the car. Or should I go through the pain staking task beforehand? Sorry @imz for jacking your thread.


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No need to apologise mate share the fun these mods are exciting times.


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I hate to be that guy but when I fitted my FMIC I studied all the options available to me and read the FMIC Sticky thread front to back, and had no trouble fitting my intercooler. I strategised it, measured things a million times, cut things once, and it fitted.

Granted, if you lack the patience of reading some how to’s, you’re not going to have a good time. But nothing good comes easy
 
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S3AMJ said:
Hey Stuart, was fitting the downpipe way easier with the head off? I know it probably should be, but you’ve got hands on experience now this is why I’m thinking I’ll let Bill do mine being as the head will be off when he’s got the car. Or should I go through the pain staking task beforehand? Sorry @imz for jacking your thread.


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For a beginner its about a million or maybe 2 million times easier depending on what you find difficult or easy.

1. With the head off you can access all 3 of the downpipe to turbo bolts and can remove and replace the studs as required.
2. You do have to remove the downpipe hanger.
3. You push the downpipe through the hole from the old one.

From below you need to lower the subframe and try not to break the steering track. TTShop charge from ~£500 (5 hours @ 75 + vat) to fit a customer supplied downpipe.
 
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Stuart B said:
For a beginner its about a million or maybe 2 million times easier depending on what you find difficult or easy.

1. With the head off you can access all 3 of the downpipe to turbo bolts and can remove and replace the studs as required.
2. You do have to remove the downpipe hanger.
3. You push the downpipe through the hole from the old one.

From below you need to lower the subframe and try not to break the steering track. TTShop charge from ~£500 (5 hours @ 75 + vat) to fit a customer supplied downpipe.
Click to expand...

Thanks Stuart for the info. As my head will be coming off, hybrid turbo fitted, etc. It’s a no brainier for me to pay bill a little extra to get him to do it. If I had more time and my car was local I’d be stripping the engine myself and doing all the work. I’m restricted to one weekend a month, that alone is only really one full days work on it...... frustrating isn’t the word. But work comes first it’s a perfect opportunity for you though! I’m looking forward to seeing your progress and results now your going the same route


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