Intercooler FMIC into A1 Caddy (56K beware)

[regcheeseman]

I picked this up new for £16  :lol: has some dented fins but nothing serious.

It's from a "erm I think a ford" :roll:  according to the seller



Made some brackets up either side, had to modify the light bracket on one side...


Fit's in nice and the rad sits back in it's original brackets    


- only problem so far is I had to shift the battery backwards 30mm to get a decent space between the rad and the battery for the intercooler tube.

no problems on the other side.


The only further snag I can see is that my hand may have been forced on the choice of fitting the four lamp or two lamp front end, the grill with spots may not fit anymore and even if it did - they will rob airflow.

[HP]

Beautiful cooler.  
Where are you gonna fit the water radiator? Behind the IC? Ain't that gonna be too restrict for the rad? It seems to me that "all" the air goes to the IC!
These big FMIC's, sometimes mess a bit with my head.  :roll:

[regcheeseman]

Had to move my battery tray back as much as possible to get the hose out from the intercooler and is a bits of a mis-mash of sections cut from hoses and rejoined.


The ally tubes are cut from a scrap damaged scaffold tower section, and polished.

Just a test fitting, which is why the hose clamps are loose/missing.

Where are you gonna fit the water radiator? Behind the IC? Ain't that gonna be too restrict for the rad? It seems to me that "all" the air goes to the IC!

Rad fit's back in it's original position, it'll only loose a slight bit of airflow and besides, i'm in the UK so it'll never actually get that hot!

[bert]

looking good clive!
Bert

[veeman]

Looks great!  I want to do a similar type intercooler... Do you know what that IC came from?  I'm trying to think of turbocharged Fords over here in the Us.

How did you move the battery back?  Did you have to come up with some other way to hold it down after pushing it back?

Can you take a shot of the IC inlet tubing there by the alternator?  I think you don't have A/C, but how tight is it there?

[regcheeseman]

Do you know what that IC came from? I'm trying to think of turbocharged Fords over here in the Us.

The intercooler is believed to have come from a Ford Focus TDCI 06 model.

How did you move the battery back? Did you have to come up with some other way to hold it down after pushing it back?

The battery move was accomplished by drilling out the welds that hold the bracket that locates the rear of the battery on the battery tray.

The bracket was re-welded as far back as possible (I think I had to grind a bit of it to suit)

A bolt was welded into the battery tray about 1" further back in order to relocate the bolt down clamp, so it all looks fairly stock.

It's not clamped down in the previous pictures, because I'm constantly lifting battery in and out at the moment and I'll confess that weld splatter damaged the thread and it needs re-cutting.
However in the picture the clamp bolt is  few turns in so you have an idea of the clamps new location.

Can you take a shot of the IC inlet tubing there by the alternator? I think you don't have A/C, but how tight is it there?

I haven't got a photo with the tube in place but here it is without....

The tubing aint very complex as you can imagine with so much space available[/quote]

[veeman]

Wow... thanks for the detailed response.  It looks like you've got plenty of room for the tubing with the non a/c setup and moved battery. I'm going to see if I can do the same thing and ditch my a/c...  

I had thought about possibly doing something like this (not my car, but kudos on a nice job to the owner), but I don't think the A1's have that much room on the battery side for two pipes...

[BioDieselVW]

What are you using for IC piping? It looks like radiator hose? Have you had any problems blowing hoses? How much boost are you running? I have a IC im about to use in my Caddy and still debating on what to use for the IC piping. Looks great! Good job!