Turbo Intercooler Mounting/rad Lowering, Whos Done It?

[inferno 1]

Ive done the search and found a few pics, but im pretty sure some of you will have more pics to upload now. so whos lowered there rad and whose fitted the intercooler in the valance? can i have a few clear pics as to how you ran the pipe work?

 

im looking to turbo my 309, but it appears to have much less space than my zx, and the 205 td rad i have doesnt fit!its actually slightly too long! im looking into the possibility of lowering the fad and fitting a cossie ic above it now.

 

does anyone have a spare ic local to me? or a v slimline fan? i used a rsturbo one last time that worked well!

[Henry Yorke 269 3 Cars]

All pipes over the top on a Fiat Punto GT intercooler. Grille fits as standard (I ground off some of the plastic lugs at the front on the intercooler)

 

How the rad is lowered on mine. Hoses were extended longer to suit

[sonofsam 5]

Im going valance mounted

Pipes goes under front cross member,so no need to drop a thing

[inferno 1]

hmmm... how safe will it be to run the pipes that low? id rather risk a stone in the rad than a stone in the intake if it got hit by anything... :S where did u get the bent pipes from? and is that a 1.9 inlet on a 2litre engine? was it much work to fit? much difference in performance?

[sonofsam 5]

Personally i dont see any problem with it being that low,pipes will be inline with the sump.That picture is just a mock up,but the mr2 ic fits neatly in my valance.

..er mesh

what are planning to hit then ?!

autoinduction.com for the pipes

[TEKNOPUG 3]

You'd be best off getting hold of a 2WD Cossie intercooler and mounting that above the rad (once you've dropped it).

[inferno 1]

yep... think illl try the cossie ic above the rad, although the punt gt ic looks pretty smart... might run 2 side by side...

[inferno 1]

ok ive had a proper look now.... i can fit the desel 205 rad in the original 309 fan cowling with minimal plastic removal. this fits snug under the 309 slam panel, leaving enough room for a 3 inch induction pipe across the top! so initialy im going with the punto ic or similar( depending on ebay).

 

however the fan is on the passenger side, so i may mount the ic in the empty fan housing on the driver side and take the boost pipe from the turbo over the top of the engine to it , rather than all around that back and over the gearbox...

 

that should leave 1 90 bend from turbo,the intercooler, and straight into the intake... in theory it looks good!!

 

than a custom made ic to fill the space of the second fan and as low as possibly when its running!

[Fuqa 0]

not everyones cup of tea, but this is how i did mine

[inferno 1]

hmmm... no i dont like that! not very suttle... yet not in your face... i like total sleeper myself, although if the ic covered the grill itd look ok...i cut the ends off my last cossie ic and lenthened them with ali angle to fill the grill of my zx.

[Malachy 0]

not everyones cup of tea, but this is how i did mine

doing a similar mount for my 306 cab conversion, using 2wd cossy intercooler (looks like what you have there)

[Fuqa 0]

doing a similar mount for my 306 cab conversion, using 2wd cossy intercooler (looks like what you have there)

 

yup mine is with a 2wd cossie ic

[sonofsam 5]

yup mine is with a 2wd cossie ic

 

Love that set-up ,looks spot on,i invested in some Kapton polyimide tape to prevent radiant heat getting to those front boost pipes..no clue if it will make any difference or not?

[Henry Yorke 269 3 Cars]

I always wondered what the effect of long pipes was on turbo lag, which is why I tried to keep mine as short as possible.

 

Inferno, I also had a R5 GTT intercooler which had 2 top pipes like the Punto. The tops pop off these though if you don't strap them up!

[Fuqa 0]

thanks sonofsam

 

@henry.... there was no effect on lag at all, infact i felt it spun up too quickly.. prob just the nature of a small turbo tho

[TEKNOPUG 3]

I'm kinda stuck with a long boost distance as the TT manifold positions the turbo exit downwards and diagonally opposite to the TB. I can't see anyway of overcoming this without a lot of work. Fitting the Cosworth I/C will actually increase the length further. Although I really can't see the difference in lag being noticeable and the hybrid T25 was chosen in the first place because of it's fast spool up time. Plus I'm running a lightened 200mm flywheel and it picks up in no time on the road.

[Henry Yorke 269 3 Cars]

Cheers Andrew. I forgot the TT system comes under the sump.

 

The long pipe lag could be one of those theoretical things that makes perfect logical sense behind your keyboard but on the open road makes no difference what so ever! Again a dump valve which stops the turbo stalling will also release the pressure in the boost pipes and therefore the system will take longer to pressurise..... hence lag!