Been busy in my garage........
13 July 2011, 10:35 PM
#32
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Inlet manifold spacers arrived today - they look great!
I cleaned up the mounting face on the engine using a bit of fine wet and dry paper.
The spacers come complete with seals that slot into a groove on them. I fitted the seals and trial fitted the spaces - perfect fit! When I fit them in permanently I will use a smear of silicone grease on the seals to stick them in place and stop them popping out during fitting.
I also sat my inlet manifold on top to see what it would look like. Can't fix this in yet as the turbo air inlet hose has not arrived yet and this will be easier to fit with the inlet manifold removed.
I cleaned up the mounting face on the engine using a bit of fine wet and dry paper.
The spacers come complete with seals that slot into a groove on them. I fitted the seals and trial fitted the spaces - perfect fit! When I fit them in permanently I will use a smear of silicone grease on the seals to stick them in place and stop them popping out during fitting.
I also sat my inlet manifold on top to see what it would look like. Can't fix this in yet as the turbo air inlet hose has not arrived yet and this will be easier to fit with the inlet manifold removed.
15 July 2011, 11:20 PM
#33
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Hoses, hoses, hoses - now where do I start!
Luckily I have the wifes forester that I can use as a point of reference as I can't remember where they all go?
Got all the breathers, coolant and powersteering hoses - just waiting on the boost hoses now. The mould for the turbo inlet is the most complicated bit so is taking a bit of time to get it right but should hopefully be done middle of next week.
Luckily I have the wifes forester that I can use as a point of reference as I can't remember where they all go?
Got all the breathers, coolant and powersteering hoses - just waiting on the boost hoses now. The mould for the turbo inlet is the most complicated bit so is taking a bit of time to get it right but should hopefully be done middle of next week.
16 July 2011, 10:51 PM
#35
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Mr Roose's hoses are of a very good quality and an excellent fit!
Today I have trial fitted them all but rain stopped play (unfortunatly my garage is only just big enough to fit the car in so Im stood outside when doing the work)
I popped into town and bought some hose clips instead - wasn't bothered about flashy stainless ones so just picked up 6 boxes full from Halfords.
Hopefully Il get them all properly fitted tomorrow and get some pics up.
Today I have trial fitted them all but rain stopped play (unfortunatly my garage is only just big enough to fit the car in so Im stood outside when doing the work)
I popped into town and bought some hose clips instead - wasn't bothered about flashy stainless ones so just picked up 6 boxes full from Halfords.
Hopefully Il get them all properly fitted tomorrow and get some pics up.
17 July 2011, 07:31 PM
#38
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For the first task of the day you will need:
One semi waterproof garage extension!
The hoses underneath the car were a bit of a pig to get on as they sit up between the cambelt cover and the engine.
The new hoses are slightly thicker than the originals. The hole in the top of the coolant resevoir wasn't big enough to take the new hose so a quick wizz with a reaming tool and in it goes.
- 5 clothes pegs
- 5 drawing pins
- A sheet of plastic
One semi waterproof garage extension!
The hoses underneath the car were a bit of a pig to get on as they sit up between the cambelt cover and the engine.
The new hoses are slightly thicker than the originals. The hole in the top of the coolant resevoir wasn't big enough to take the new hose so a quick wizz with a reaming tool and in it goes.
Last edited by C8 DHC 04WRX; 17 July 2011 at 07:34 PM.
17 July 2011, 07:50 PM
#39
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Fitted the oil draw off hose to the base of the turbo then secured the turbo into place, reconnected exhaust, added as many of the coolant hoses and breathers hoses I could before the inlet goes back on.
I greased up the o'rings on the manifold spacers to stop them falling out during fitting, then put the inlet manifold in. The spacers came with new bolts but they are too long and bottom out before they are tight - will have to contact Carl Davey about this?
The new bolts are approx 15mm longer than the originals but the spacers are only 8mm thick
There looks to be enough room to feed the turbo inlet hose in once it arrives wed/thurs this week
All hoses fitted (just need a couple more hose clips as Halfords had run out of the smaller sized ones), fuel lines reconnected, airbox and washer bottle back in too
I trial fitted the intercooler to make sure it doesn't foul the undertray now the manifold spacers are fitted - it was ok. It has to come out again once the boost hoses arrive.
I also need to route the cable for the oil temp gauge (black and white wire coiled behind brake fluid resevoir) but I have ordered some heatproof sleeving to protect it as it will run close to the exhaust.
I greased up the o'rings on the manifold spacers to stop them falling out during fitting, then put the inlet manifold in. The spacers came with new bolts but they are too long and bottom out before they are tight - will have to contact Carl Davey about this?
The new bolts are approx 15mm longer than the originals but the spacers are only 8mm thick
There looks to be enough room to feed the turbo inlet hose in once it arrives wed/thurs this week
All hoses fitted (just need a couple more hose clips as Halfords had run out of the smaller sized ones), fuel lines reconnected, airbox and washer bottle back in too
I trial fitted the intercooler to make sure it doesn't foul the undertray now the manifold spacers are fitted - it was ok. It has to come out again once the boost hoses arrive.
I also need to route the cable for the oil temp gauge (black and white wire coiled behind brake fluid resevoir) but I have ordered some heatproof sleeving to protect it as it will run close to the exhaust.
19 July 2011, 11:16 PM
#40
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Coolant system now full with no visable leaks.
Fitted the oil temp probe in place of the sump plug.
My HEL oil cooler that I ordered from Indigo-GT arrived last week with bits missing and the replacements have still have not arrived yet - just emailed them again to get things moving. Anyway, have worked out the route for my oil cooler pipes but they come a bit close to the exhaust heat shield. Got the trusty angle grinder out and took a little bit off.
I also have some heat proof sleeving to protect the oil cooler hoses where it runs close to the exhaust.
http://www.thermalvelocity.co.uk/Lin...eve/p-114-421/
Fitted the oil temp probe in place of the sump plug.
My HEL oil cooler that I ordered from Indigo-GT arrived last week with bits missing and the replacements have still have not arrived yet - just emailed them again to get things moving. Anyway, have worked out the route for my oil cooler pipes but they come a bit close to the exhaust heat shield. Got the trusty angle grinder out and took a little bit off.
I also have some heat proof sleeving to protect the oil cooler hoses where it runs close to the exhaust.
http://www.thermalvelocity.co.uk/Lin...eve/p-114-421/
20 July 2011, 09:48 PM
#41
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This is the heat proof sleeving over the oil cooler hoses. There is just enough room next to the hose to run the cable down to the oil temperature sensor
Carl Davey is sending me some more bolts for the inlet manifold.
Roose motorsport have been in touch and the turbo inlet hose is not going to be done in time for the remap on friday. I have rung Simon today and he is going to ring me back and let me know when he can fit me in for mapping. I was really looking forward to driving her again this weekend - never mind!
Got some water spary jets for the intercooler. Simply drilled the undertray and stuck them in place with araldite.
They are actually off a Insignia - they have a slitted opening and give a wide 'fan like' spary so should cover the intercooler nicely!
Carl Davey is sending me some more bolts for the inlet manifold.
Roose motorsport have been in touch and the turbo inlet hose is not going to be done in time for the remap on friday. I have rung Simon today and he is going to ring me back and let me know when he can fit me in for mapping. I was really looking forward to driving her again this weekend - never mind!
Got some water spary jets for the intercooler. Simply drilled the undertray and stuck them in place with araldite.
They are actually off a Insignia - they have a slitted opening and give a wide 'fan like' spary so should cover the intercooler nicely!
25 July 2011, 10:46 PM
#44
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Got a 'trial' turbo inlet hose to test the fitment. My one will be black.
It is a bit tighter than the original in a few places due to the increased hose wall thickness but fits ok. They are now going to add the hose take-off's to the mould and produce the finished article for me
It is a bit tighter than the original in a few places due to the increased hose wall thickness but fits ok. They are now going to add the hose take-off's to the mould and produce the finished article for me
29 July 2011, 01:41 PM
#46
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Red hose will be binned - it is just something they knocked up in 5 mins so that we could check the angles/clearances and wouldn't work as a functional hose. I marked it up where it was rubbing in a couple of places and they have adjusted the mould accordingly. Going to pick up the finished hose today and will get some photo's up once finished.
If you want to buy a hose then they are going to let me know prices once everything has been finalised and they should be able to offer a group buy on these - watch this space!
If you want to buy a hose then they are going to let me know prices once everything has been finalised and they should be able to offer a group buy on these - watch this space!
01 August 2011, 12:00 AM
#47
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Picked the finished turbo inlet hose up on friday.
It is tight getting in in but fits perfectly!
Also topped up power steering fluid. After a bit of searching it turns out you use auto transmission fluid!
It is tight getting in in but fits perfectly!
Also topped up power steering fluid. After a bit of searching it turns out you use auto transmission fluid!
04 August 2011, 09:21 PM
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04 August 2011, 09:41 PM
#52
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Finally got some oil cooler hose and the mounting bracket so cracked on with the oil cooler fitting.
To get it tight on one side I removed a bit where the headlamp/grill bracket sits. Put some card behind to protect the fins.
Then cut using a hacksaw
Fitted the mounting bracket - also made up a couple of small brackets to hold it all in place.
Oil cooler and pipe then installed
Ran the pipe down through the inner wing
Then into the sleeving around the back of the exhaust and onto the sandwich plate. Used metal tie wraps here to hold it all in place. The fittings onto the sandwich plate are on copper washers and had to be mega tight to make them seal!
Bumper refitted and quite a stealth install (just want to spary the bracket black at a later date)
To get it tight on one side I removed a bit where the headlamp/grill bracket sits. Put some card behind to protect the fins.
Then cut using a hacksaw
Fitted the mounting bracket - also made up a couple of small brackets to hold it all in place.
Oil cooler and pipe then installed
Ran the pipe down through the inner wing
Then into the sleeving around the back of the exhaust and onto the sandwich plate. Used metal tie wraps here to hold it all in place. The fittings onto the sandwich plate are on copper washers and had to be mega tight to make them seal!
Bumper refitted and quite a stealth install (just want to spary the bracket black at a later date)
04 August 2011, 10:08 PM
#53
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Car was mapped by Simon (JGM) on monday.
332 bhp and 333 torque
Simon is going to email me the graph so I will post it up soon.
Roll on September trackday at Cadwell Park!
332 bhp and 333 torque
Simon is going to email me the graph so I will post it up soon.
Roll on September trackday at Cadwell Park!
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