Nialls supercharged GTi6 - project tidy up

[Niall]

So today has consisted of not a lot except for a bit of planning and design.
The charger outlet i originally designed would of been ideal except for three things.
The engine actually sits at 30 degrees instead of the 15 i thought so we made the outlet wrong meaning it didn't fit down in front of the rad and we had to turn it 90 degrees and spectacularly bodge it together as you have seen before.
The plate is made from steel and the charger is ally so they expand at different rates which has caused the plate to buckle and leak air
The pipework to the intercooler runs along the top of the intercooler and then around the back of the rad meaning a huge run of pipework which i really want to reduce and that air thats going into the intercooler will be even hotter than it would if it didn't go that route. On the dyno, temperatures of almost 50 degrees were seen which is far from ideal!
Also, the plate is leaking since its buckled meaning I'm only getting 4psi boost (may be more but haven't really booted it yet lol).

So, time to design a new one. I was temped to get a new IC which would allow the O/S pipe to run around the chassis leg and up where the washer bottle would be but then i realised i don't have a massive fan cowling in the way so...

[attachment=14810]

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So instead of that pipe going all the way along the top of the IC, it will join the silicone from the IC with a 90, straight up past the rad and straight into the front of the charger with the new plate.
Hoping the new plate will be made by the end of the month, will be made out of aluminium this time so will expand closer to the chargers expansion rate and the plate that will bolt to the charger will be made of 10mm aluminium instead of the 3mm steel i currently have.

[attachment=14813]

This is the first design for the new outlet but I'm sure it will change over the coming week. As soon as I'm happy with it, i will send it off to be made unless anyone on here is handy with a sheet of aluminium and a TIG?

Oh also ordered a Walbro fuel pump and a new green cotton air filter