Project S2 Cossie Intercooler

**Adam_Ash** · 30-06-2002, 17:17

Started my intercooler (TA GUINLESS) today cos now ive got my ACT guage, i can see what temp it is getting to now

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So, ive been getting the parts together for a couple of weeks now so today was i/c installing time. Had to get rid of the old fan cos it was a xr4x4 one(i think) and it was massive. Got the RST one (CHEERS RED DEVIL) in very easily and held in place with zipties for now until my brackets arrive! pretty easy job really, untill i came to connect the hoses up when i find out one the reducer ones are split! gutted. so i had a quick fone around and Steve (aka Guinless) says he can help me out. Thanks again to Steve, top bloke and luverly cossie too. Cheers to TimB for the ally pipework.

Anyway, a few pics. Bumper getting fitted tomorrow, cos it started raining and goin dark. not good. least ill have plenty of time to do it properly.

**Adam_Ash** · 30-06-2002, 17:21

Right, we are finished and well happy with the i/c 's capabilities!

Cheers again to Tim for the advice last night. Thought i'd killed it!!

Anyway, got everything re-fitted again this morning, and the thing wouldnt start! so got it towed around the block trying to bump start it and nothing!! (well engine started but throttle did nothing, not even rev it!!) so had a quick wiggle of some sensors and it starts up on 1 turn of the key...wiered!

Out for a power run, got some funny looks with i/c sticking out front of car, but it goes well, ACT's are miles lower and there is no noticeable extra lag, which i am happy with.

Got it back to home only to find that my radiator is ****in water out from a tiny crack near the top-hose mount. GUTTED! My mate turns up with some of this wiered glue for using on model boats. Well rad out, clean up, glue on, dry, epoxy stuff over it, dry, back in, all hoses and i/c reconnected AGAIN.

Start on bumper. God what hard work that was with a hacksaw, so off to my mates house to use his compressor and air cutter thing. Sorted.

Just need to relocate number plate now and buy a bit of mesh type stuff.

Couple more pics

**Threedoorboy** · 01-07-2002, 13:09

Nice work fella!

**fivedoorboy** · 16-03-2003, 20:40

Looks wicked,has it made much difference,i'm up for the conversion myself,(got an intercooler kicking about)not to keen on going the PACE route and tucking it out of the way,i like to see intercoolers out front,and in the airflow,especially as people won't know what to make of an escort 5 door with an intercooler sticking out of the standard black plastic bumper!

**FF_Mark** · 02-05-2003, 18:34

Who did you pipe work ?

Think thats going to be the biggest pain, finding some to do that.

Why didnt you put the outlet round the other side of the rad ?

**Adam_Ash** · 02-05-2003, 19:01

My next door neighbour did it for me FOC

, he even rolled the pipework from a flat piece of aluminium.

Any Welding place should be able to knock it up for you.

I did it this way because it was the easiest way basically. No need to relocate the radiator, all I had to do was make some brackets out of steel for the IC mounting.

It is really easy and made a vast improvement to my car.

Another piccie of it too.

**AndyGranger** · 04-05-2003, 21:01

I,ve got stainless exhaust pipe on mine works a treat!!

**rstonypastie** · 13-05-2003, 20:59

what sort of act,s are you now getting? might do that instead of a GRS cos i am only going to run 10-15psi so it will work fine

**Adam_Ash** · 13-05-2003, 21:40

I have not seen (bad english) more than 40 degrees up to now.

Works perfectly and the angled corners have not caused any problems what so ever (although peolple said it would matter).

All in all, not bad for nothing