Paul's estate mk2 - air intake on

[Paul_13]

After the last one died a premature death I decided to get another! 

Here's the dirty slag 



When I got I pretty much mapped it straight away, although I think I buggered the hp pump as it's no where near as fast as my last one. (the fuel pipe blew off on the way back from picking it up as I was driving) 

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Is pretty specced up suss pension wise with a rebuilt beam, grp n rear shocks and b8?  Front shocks and eibach springs.

I took the vts wheels off straight away as I didn't like them and put the cyclones back on. Decat is fitted already

Jobs to do:

Raise rear
fit solid beam mounts
fabricate a back box
Fit slim line fans (as I've removed the fan cowling)
fit intercooler and swap inlet elbow etc
fit 6 flywheel &  dturbo clutch
Fit d turbo clutch cable
R70 pump
stage 2 Remap

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[silverzx]

Best colour imo.

[Frosty]

Glad to see you have got another 1 mate. Sounds like some good plans for it

[7057sam]

great spec and colour

looking forward to the end result

[Paul_13]

Got to say I much prefer the colour compared to the last one

[7057sam]

Yeah i think the china's do look more modern

What power are you hoping for when it's done?

[Paul_13]

Optimistic 170bhp and a gazillion torques!
No honestly whatever over standard I'll be happy with

I had a bit of fun with the hand brake this morning.
The response is like waiting for the titanic to do a u turn!
Once it was out it was reluctant to snap back in!
if it snows again I'll get the 205 out. I forgot how fast the damn thing was
I do miss driving that in the snow, reverse 1080 spins were loads of fun

[Paul_13]

Bit of progress with the intercooler, just a few pics to help other people if they're doing the same.

I'm hoping the pipes will squeeze through, I'm going to shove the rad over see if it will give me any more clearance. They're reduced elbows and reduce down to 2"

[rryan]

when you come round later, i will get a list of parts i need to buy

What size is the IC?

[Paul_13]

Yeah no prob
I'll measure the length of that pipe above the cooler
I haven't actually held it up yet to see if it fits central. There's a fair bit of meat on the pipes to chop off to give it some movement

Started raining a bit so I've given up trying to remove the bumper

[silverzx]

I can confirm 2" goes around a ph3 HDi radiator on the passenger side.

[Frosty]

You running the pipe above the intercooler?

[Paul_13]

Ok cheers trent

Yes frosty, that's the plan. What you thinking?

[Frosty]

Should be fine. On my estate i got the pipe running underneath, it is a pretty low though. Be interesting to see your complete set up when all fitted

[Paul_13]

Like I said before was planning on doing a guide for it so I'll do it step be step

[Paul_13]

Clutch is now slipping like mad grrr....

Any way I cleaned it

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Excuse the steelie that pesky paving slab gave me a puncture

[mr_fish]

Should look fairly neat and tidy on that intercooler install

Will be interested to see how you get on.

[Paul_13]

Acquiring a load of materials from work to mount the intercooler.

Just need a bit of time to pipe the thing up

[shervo]

I routed my pipes like that and I managed to get 60mm through with a minor cut. So you should be fine with 50mm.

[titch]

2" fitted passed the rad with no problems on mine. Without any trimming or cutting, so you should be fine.

[Paul_13]

Sweet

[7057sam]

Cleans up nice Paul

When you doing the pipe work and intercooler

[Paul_13]

I've been a bit lazy, got a lot going on at the moment.

Need to get brackets sorted out first

[Paul_13]

Relocated the tps Flipped the bracket and drilled a hole in the slam panel

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IC fits not a problem, hoses go around the rad easily

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Trimmed down the 180' pipe a bit and made a double sided clip

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This bracket is going to be a problem, what have people done with it before? If I take it off I lose the cold air feed

I want to retain the standard air box

[Paul_13]

Tomorrow's job is to get the intercooler supported, maybe connect everything up. But I need to order a 57/51mm reducer 90 to connect into the pipe coming off the turbo

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Or bodge the 51mm on for the time being

[Paul_13]

Right big update today, well just lots of pictures!

Fitted the front mount and plumbed it all in. I'll make a guide on this when I get time

I fixed the intercooler through the bottom panel, used the existing hole (removed the clip)

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Drilled a hole in the slam panel and put a bit of 8mm rod through.
IC is solid and doesn't move now.

IC sits dead central and the hoses either side needed trimming 10mm

Just to note I have kept the radiator in the standard position

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The only bit that needed modifying was the slam panel. It needed pulling towards the front bumper a little to clear the 180 degree hose

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Pic of the pipes down the side

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Where it leads to

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I'm going to change this a bit as I'm not happy with it
the 90' in the middle will be alloy instead of silicon

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The cold air feed is retained

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I cut a bit off the 406 top pipe, this ends up being 2" when you do so

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The old inlet elbow and air doser removed

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Where it came from

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This was an absolute twat to remove, easiest way was a hacksaw after undoing the jubilees, one on the turbo (accessible from the wheel arch) and one on the inlet elbow/air doser (accessible from under the car through the exhaust tunnel)

Very restrictive design down to around 1" in places

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New all alloy inlet elbow

[Paul_13]

Here's the bottom turbo pipe, a thanks to Allenallen (sp?) on this one. The pipe is not a direct fit!

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Here's the bits you need to trim

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The part of the subframe that needs relieving (I was in a rush so this could be done neater

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Turbo pipe fitted. The PAS pipe gets right in the way

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Then a 90/90 to bring you back to the intercooler

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All back together! My air duct bolt had sheared off hence the cable tie

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Nice and subtle

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I'll list all the bits I've used when I get a chance

[MY95]

Nice work! Will look forward to more updates and it all being finished
You fitting a bigger turbo in the long run or staying with the standard one?

[titch]

Looks great !!

[andyyy]

Looking good pal, have you sorted / found out why it's down on power?