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Author Smoke Grey GSi Turbo Project.
thegsi
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Registered: 3rd Feb 07
Location: Kidderminster Drives: Evo (you can't afford one)
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9th May 09 at 09:02   View User's Profile U2U Member Reply With Quote
Update:

Began building my boost pipes today. Before, I was using a real makeshift 60mm straight hose set up which was horrendous. Due to a budget, it was all I had to get the car running but due to lack of reducers etc. boost pressure was leaking everywhere
So instead of buying a ready made kit from Ebay, I decided to build up the pipework myself. I went for Viper 45mm joiners with a 51mm hard alloy pipe:




We got the top hat and DV joined up but I'll need to order some more hoses to join to the IC and turbo. I'm going to have to use flexihose from Viper as the angles are pretty queer.

How it will look:



We had a test fit of the 8.1L Merc C Class IC I've had for a while now. We were toying with the idea of fitting it but the outlet sizes are near to 70mm and there's no point at the current state of tune (plus I really can't afford to get phase upgrade ATM!) but this will be going on soon!



Bumper's at Robs being touched up thanks to tow bar beating:


Thats all for now!

fazza
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Registered: 7th Feb 08
Location: Plymouth
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9th May 09 at 09:13   View User's Profile U2U Member Reply With Quote
looking sweet mate.

will that intercooler outlets fit between the crossmember bit?
thegsi
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Registered: 3rd Feb 07
Location: Kidderminster Drives: Evo (you can't afford one)
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9th May 09 at 09:17   View User's Profile U2U Member Reply With Quote
quote:
Originally posted by fazza
looking sweet mate.

will that intercooler outlets fit between the crossmember bit?

Na it'd need to be cut mate. Not a great deal but just enough to recess back in under the oil cooler. It's not much deeper than the standard one either so wouldn't need to cut the bumper.

[Edited on 09-05-2009 by thegsi]
Nic Barnes
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Registered: 5th Apr 04
Location: nowhere near ginger people
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9th May 09 at 12:13   View User's Profile U2U Member Reply With Quote
tbh, plastic end caps just arent the best anyway. can get proper metal end caps on intercoolers these days on ebay for 100 odd quid. jbi motorsport sell a one that seems a decent size and fit.

boost pipes lookin neat though. red pipes are way better than blue.
Scotty C
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Registered: 6th Nov 05
Location: Kidderminster Drives: 1.6 16v Sport
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9th May 09 at 13:25   View User's Profile U2U Member Reply With Quote
Loving it Jay, Really am.

That IC looks fanstastic. I would go as far to say this is my favourite GSi
thegsi
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Registered: 3rd Feb 07
Location: Kidderminster Drives: Evo (you can't afford one)
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10th May 09 at 14:36   View User's Profile U2U Member Reply With Quote
Cheers Scott! Where have you been?
thegsi
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Registered: 3rd Feb 07
Location: Kidderminster Drives: Evo (you can't afford one)
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10th May 09 at 15:04   View User's Profile U2U Member Reply With Quote
Did a few more bits and bobs to the car again today. Gave the IC a fresh lick of paint:


The manifold is looking a bit tatty and it irritates me. I've tried to sand it back, polish it but it still looks shit. Shy of having it coated, I can't think of much else what to do so to kind of cover it for function and style I'm going to make a heat shield. It will be the same as my current one but with an extra part to cover the manifold but leave the actuator open so it can be accessed:

Red indicates where it'll sit:


Finding the angle which is 65deg.


And the template which is made from stainless. I'll take into work tomorrow to be cut and bent. Fingers crossed


and some shiney new stainless hose clips. Got 15+ of these babies
Nic Barnes
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Registered: 5th Apr 04
Location: nowhere near ginger people
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10th May 09 at 15:11   View User's Profile U2U Member Reply With Quote
turbo cover idea is good. there isnt really a lot you can do to make a lump of cast look good. it will always go back to look crap due to heat etc on it.
thegsi
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Registered: 3rd Feb 07
Location: Kidderminster Drives: Evo (you can't afford one)
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10th May 09 at 15:43   View User's Profile U2U Member Reply With Quote
quote:
Originally posted by Nic Barnes
turbo cover idea is good. there isnt really a lot you can do to make a lump of cast look good. it will always go back to look crap due to heat etc on it.

Cheers Nic. Yeh the only other thing I was thinking was heat wrap but can't imagine that'll be too easy to do.
cayenne15
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Registered: 28th Sep 08
Location: Cheslyn Hay, Staffordshire
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10th May 09 at 18:12   View Garage View User's Profile U2U Member Reply With Quote
looking good Jay!! is it gonna all be done before PVS?
Danny W
Organiser: East Midlands
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Registered: 14th Nov 05
Location: Northamptonshire
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10th May 09 at 18:15   View Garage View User's Profile U2U Member Reply With Quote
good progress on this Jay, looks brilliant.. congrats on the may feature cars too

Smoke Grey 5 Door

EastMids Regional Events
thegsi
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Registered: 3rd Feb 07
Location: Kidderminster Drives: Evo (you can't afford one)
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10th May 09 at 18:17   View User's Profile U2U Member Reply With Quote
Cheers lads! Yeh Luke it will be done before PVS. Touch wood!
Nice one Danny cheers mate. Will you be joining our convoy to PVS sir?
Danny W
Organiser: East Midlands
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Registered: 14th Nov 05
Location: Northamptonshire
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10th May 09 at 18:28   View Garage View User's Profile U2U Member Reply With Quote
I'll be at pod all weekend but literally live 15 mins away i'm assuming you will be coming down the a14 kettering then through wellingborough?

Smoke Grey 5 Door

EastMids Regional Events
thegsi
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Registered: 3rd Feb 07
Location: Kidderminster Drives: Evo (you can't afford one)
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10th May 09 at 18:38   View User's Profile U2U Member Reply With Quote
Oh yeh of course! Meeting us dorks would be silly then! Yeh mate we'll be coming that way. We'll meet up with you mate
john_c20xe
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Registered: 10th Feb 08
Location: Eastbourne, EastSussex
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10th May 09 at 20:06   View User's Profile U2U Member Reply With Quote
nice work mate
thegsi
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Registered: 3rd Feb 07
Location: Kidderminster Drives: Evo (you can't afford one)
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10th May 09 at 20:12   View User's Profile U2U Member Reply With Quote
quote:
Originally posted by john_c20xe
nice work mate

Cheers bud. Have you sorted your CV's yet?
Danny W
Organiser: East Midlands
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Registered: 14th Nov 05
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12th May 09 at 17:12   View Garage View User's Profile U2U Member Reply With Quote
Jay, Are you quite handy with the old stainless steel? making the heat shield yourself?

Smoke Grey 5 Door

EastMids Regional Events
Scotty C
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Registered: 6th Nov 05
Location: Kidderminster Drives: 1.6 16v Sport
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12th May 09 at 17:25   View User's Profile U2U Member Reply With Quote
quote:
Originally posted by thegsi
Cheers Scott! Where have you been?


All work and no play mate, same old really.

I'm thinking about going to PVS. Who are you going with?
thegsi
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Registered: 3rd Feb 07
Location: Kidderminster Drives: Evo (you can't afford one)
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12th May 09 at 17:39   View User's Profile U2U Member Reply With Quote
quote:
Originally posted by Danny W
Jay, Are you quite handy with the old stainless steel? making the heat shield yourself?

Kind of mate. I got a sheet of stainless from a chimney flue makers then just making up some templates for the heat shield. Its all cut I've just got to bend it now. Have to see how it goes I guess
thegsi
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Registered: 3rd Feb 07
Location: Kidderminster Drives: Evo (you can't afford one)
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12th May 09 at 17:41   View User's Profile U2U Member Reply With Quote
quote:
Originally posted by Monster
quote:
Originally posted by thegsi
Cheers Scott! Where have you been?


All work and no play mate, same old really.

I'm thinking about going to PVS. Who are you going with?


Once my cars runnin mate, we'll go out as I said. I think my mate Matt is coming with me. You gotta come mate
Danny W
Organiser: East Midlands
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12th May 09 at 18:01   View Garage View User's Profile U2U Member Reply With Quote
quote:
Originally posted by thegsi
quote:
Originally posted by Danny W
Jay, Are you quite handy with the old stainless steel? making the heat shield yourself?

Kind of mate. I got a sheet of stainless from a chimney flue makers then just making up some templates for the heat shield. Its all cut I've just got to bend it now. Have to see how it goes I guess


ah yeah cool been thinking of making a small cover to hide my grubby radiator will be similar to how your heatshield sits but bolted to the slam panel. Difficult to do yourself? and get a nice clean cut?

Smoke Grey 5 Door

EastMids Regional Events
thegsi
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Registered: 3rd Feb 07
Location: Kidderminster Drives: Evo (you can't afford one)
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12th May 09 at 19:50   View User's Profile U2U Member Reply With Quote
Oh right. No mate not at all. I used some lead snips from work to cut it so the edges aren't too bad. Once its done, I'll put some pics up. If you think it looks good, I'll try and make you something if you send the measurements. Providing I can get some more sheet.
thegsi
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Registered: 3rd Feb 07
Location: Kidderminster Drives: Evo (you can't afford one)
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13th May 09 at 20:19   View User's Profile U2U Member Reply With Quote
Heat shield cut. Had a dummy fit but just need a fine tune and obviously a polish.
Nic Barnes
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Registered: 5th Apr 04
Location: nowhere near ginger people
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13th May 09 at 20:52   View User's Profile U2U Member Reply With Quote
will look great that id say
cayenne15
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Registered: 28th Sep 08
Location: Cheslyn Hay, Staffordshire
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14th May 09 at 16:08   View Garage View User's Profile U2U Member Reply With Quote
will look nice that Jay!! good work

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