Here are the pics of my completed project. Hope you like.



https://img.photobucket.com/albums/v...C/57bb6760.jpg

https://img.photobucket.com/albums/v...C/68f31507.jpg

https://img.photobucket.com/albums/v...C/f3fa80a6.jpg

and more...



https://img.photobucket.com/albums/v...C/c8503e55.jpg

https://img.photobucket.com/albums/v...C/bb04f97d.jpg

https://img.photobucket.com/albums/v...C/2cfdf8ba.jpg

still more...



https://img.photobucket.com/albums/v...C/8f0a9381.jpg

https://img.photobucket.com/albums/v...C/DSCF0211.jpg

https://img.photobucket.com/albums/v...C/DSCF0213.jpg

https://img.photobucket.com/albums/v...C/DSCF0214.jpg

-ebay 24x12x3 core | 3in id/od

-2.5in butt welded/mandrel bent aluminum tubing

-silicone couplers/reducers

-higgi tb adapter

-custom steel mounting brackets

-ss regular hose clamps

-welded nipple for bac valve and some other idle valve



-bov will be welded later, i think on the turbo side

-waiting on shorter air filter, will only make hard pipe if i go EMS

-have to cut a few mm's out of the lower headlight frame

-will have upper radiator panel made

-same with lower ducting

-oil filter is accessible

-spark plugs will be removed from under the car now

-everything is a very tight fit, don't know how engine vibration will affect it yet ...will adjust rb engine brace to be stiffer

-car was damaged by previous owner, noticable by the black primered areas that started to show rust

-battery in the passenger bin

-relocated pcv valve slightly

-tb cable is ziptied in



that's it for now ...don't ask about cost https://www.nopistons.com/forums/pub...O_DIR#>/11.gif ...it is a rewarding experience to make something work from scratch



only problems were two vacuum leaks that i fixed immediately and kicked myself in the shin for making



IF you saw this on another forum I apologize. I am just proud of it and I get that way when I make something from scratch.

looks good. nice work https://www.nopistons.com/forums/pub...IR#>/bigok.gif

Looks real nice! How long did it take you to fab it up?

that looks FANTASTIC!

it looks good, have you tried putting the bumper back on?

Thank you guys!



It took a while to complete because of the 30 min after work I had before all the specialty shops closed. But fabbing up the brackets took a day. Passenger side pipe routing and driver side pipe routing took a day each. Planning took a day, and final revisions took a day. So, about a week. It was about 2 weeks for install though ...and I am still waiting for parts to be delivered.



Bumper won't fit directly. I could have moved the bottom of the IC back some but then I would be hitting the bracket, or if the bracket wasn't there the bumper reinforcement mounting face. The lower half of the opening will loose up to an inch I think, no more. I am looking around for other bumper options that have more room, mine is showing signs of age as well.



I have more pics of the brackets, and before the piping was installed ...also any other angle anyone wants to see.

Yep, that's a front mount alright.

yep. sure is. powder coat?

hmm

yo that looks great...very nicely done

Very nice, it looks professional. What tipe of welder did you use?

Thanks Rocket.



[quote name='rx7chick87' date='Jun 10 2005, 08:29 AM']yep. sure is. powder coat?

hmm


[/quote]



No, silicone spray paint enamel. Satin finish. I didn't want anything too shiny, and I think this turned out good for $9 in paint. In the future I may have them powder coated or ceramic coated or polished, idk. But for the time being the paint works for me https://www.nopistons.com/forums/pub...IR#>/smile.png





[quote name='RONIN FC' date='Jun 10 2005, 09:08 AM']Very nice, it looks professional. What tipe of welder did you use?


[/quote]



Thank you. I didn't do the welds personally ...had 2 different shops weld them. If you would like I can get close up pics and maybe you can determine the type. It looks TIG though.



*forgot to mention that because of my OCD ...it took a whole day to align the IC, angle and center.

I wouldnt be able to tell, im a noob to welding. But im interested in buying a welder and I thing tig is what I need.



I always heard it should be closest to the TB.

Hmm... all the Greddy kits I have seen have them closer to the turbo.



If the turbo is what the BOV is protecting and as soon as the tb plates are closed, then all the air that is on the hot side of the intercooler piping will be sucked into the blades?

30 mph pole, with a bumper.

the frount mount will act like a bumper duh. it's his car let him do what he want's, no need to play mom, and dad here, he's made up his mind.

[quote name='nismo convert' date='Jun 10 2005, 09:55 PM']the frount mount will act like a bumper duh. it's his car let him do what he want's, no need to play mom, and dad here, he's made up his mind.


[/quote]



Don't worry about it. He posts that in a lot of FMIC topics. Fortunately I am a responsible and good driver.

It helps if you have the driving skills to avoid those pesky poles...

I think having the BOV closer to the TB would help build boost pressure quicker after re-opening the TB. You're not allowing all of that air to move all the way back through your piping, you're letting it flow a) into the engine or b) through the BOV. That's opposed to a) into the engine, b) through the intercooler and all pipes involved, and c) through the BOV.

Looks good, but what are you going to do about the hood scoop now that the top mount is gone? Are you going to block it off or let it push air into the engine bay?

[quote name='SidewaysFC' date='Jun 10 2005, 03:03 PM']Hmm... all the Greddy kits I have seen have them closer to the turbo.



If the turbo is what the BOV is protecting and as soon as the tb plates are closed, then all the air that is on the hot side of the intercooler piping will be sucked into the blades?


[/quote]

I think the theory behind it is to keep the air flowing in the same direction, even when the plates are closed and bov open. You know, the whole "inertia of moving air" thing.



Does it really make a difference either way, dunno.

Alright, I think I'll have it closer to TB then. Yeah, I don't think there will be a noticable difference in protection anyway.



About the hood scoop. I don't have any plans with it right now. Getting a reverse flow insert is pointless because it's about $250. The closest decision I have is to sell the stock one and get a new vented hood. Jim has a really nice one, don't know the price of it though.

that looks great man

whow... big front mount, and not a hackjob either like so many. Nice work!!! i'm jealous.

wheres the oil cooler mount?

[quote name='DJ Blu' date='Jun 11 2005, 07:37 PM']whow... big front mount, and not a hackjob either like so many. Nice work!!! i'm jealous.


[/quote]



Thanks :0





[quote name='nopistons94' date='Jun 11 2005, 08:06 PM']wheres the oil cooler mount?


[/quote]



Stock location.



I think the bumper turned out halfway decent. I am still trying to find a bumper that will give me more room in the back.



Yikes, those pics turned out awful after I uploaded them. Oh well, you get the point I hope.

sorry im not familiar with the stock location on a Fc, where is it? Did you have it off in the pics, maybe im just blind

leave the bumper alone, it looks fine

[quote name='Rob x-7' date='Jun 12 2005, 10:41 AM']leave the bumper alone, it looks fine


[/quote]



I will for a little while. I would rather use the full effect of the height if I could, plus it is starting to look nasty ...red speckles, cracking paint, torn left brake vent.



Stock location on the FC is right in front of the radiator, below the a/c condensor yet still in front of that as well.

I like it, looks good. Though, why not run 3 inch piping off the cold side?

Colder air is more dense and takes up less volume. After it hits the core the same amount of air now has even more room to flow since the pipe is still 2.5 inches. I think that's why https://www.nopistons.com/forums/pub...IR#>/smile.png



Either way...Greddy kit comes 2.75 out of the core and is good for quite a bit of power. More than I plan to make.



On side note ...I finally had the feeling of blowing a hose off. Boosting, then I let off and BOOM! ...then the car flooded. It scared me as if the motor popped. Then it started and idled fine and boosted fine back home. Still need to check it out to be sure.

Nice job! Where in FL ya from?

I live permanently in Tampa, but go to school up at Tallahassee in the fall.

chop the whole thing off like 1FASTT2 did

I think the S5 nose has more room in that area.

[quote name='Rob x-7' date='Jun 12 2005, 10:41 AM']leave the bumper alone, it looks fine


[/quote][quote name='Rob x-7' date='Jun 13 2005, 04:55 AM']chop the whole thing off like 1FASTT2 did


[/quote]



make up you mind https://www.nopistons.com/forums/pub...1047683561.gif https://www.nopistons.com/forums/pub...#>/biggrin.png



Yeah, I had planned on doing that, but idk still. It looks fine now, but if I could be making the intercooler more useful by cutting the bumper larger like he did then I will. I just don't want it to look ghetto. I have to see his car again and decide.





[quote name='RONIN FC' date='Jun 13 2005, 07:56 AM']I think the S5 nose has more room in that area.


[/quote]



Ok, your the third person who has mentioned that. Somehow I am going to have to take measurements to verify.

Looks good, have fun with it.

Superb job. It looks professional. The bumper is fine, keep it stock, and buy a stocker bumper.



For the hood: Get a stock S4 N/A hood. Aluminium to be specific.