Cutting into the front panel, under front bumper
Turbo Mini Forums

im wanting to fit my 2wd cosworth intercooler to my mini and i want to fit it under the front bumper where the front numberplate sits. I want to mount it there, with two boost pipes running upwards through the front panel (hidden). Is it ok to cut metal out of this part of the front panel though?

If it helpsill get some photos to show where i mean. Because the intercooler is black it might look quite good and stealthy

Previous Engine: 1040cc Morespeed engine, 1275 turbo head T2 Turbo Mirage Manifolds Megajolt
Previous engine: STD metro turbo, megajolt
Drives: 399bananahp (flywheel) Honda Civic Vtec b18c4 T28 Turbo 1968 Mini

Megajolt maps to download: http://www.jamesfawcett.co.uk/cms/index.ph...&gid=3&Itemid=3

I cant see a problem with this as long as you fit all solid front subframe mounts, I dont mean polyflex bushes though.
Paul

I seriously doubt it!

is the front subframe front crossmember not right behind the numberplate/valance feebs?

in all honesty feebs, i dont want you to cut your bodywork away! its too nice a car to risk it!!

"Turbo's make torque, and torque makes fun"

"did you know you can toast potato waffles?"

i'm going to be cutting the metal between the front panal mountings away, i have solid mounts, its just a flappy piece of tin like the rear valance, only inboard of the mounting points though,

SKYLINES ARE LIKE CLITS, EVERY FLANGE SEEMS TO HAVE ONE: see this sticker on my silvia

the Search-section on this forum is blummin superb & simple to use, unlike some other forums, without the search-section & the help of this bunch of chaps on here i'll never be able to !!!Start the day with a 998cc turbo!!! :) i'm getting closer though!

Tom Fenton says: I have it all, make me an offer

Hi,
The only problem I see with the idea is trying to get the boost pipes to it, as the front subframe is surely going to be right in the way.
From a structual point of view, I'd leave the corners of where you cut a little rounded so a no cracks can spread out from there.
Cheers,
Gavin :)

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Good call there Bat, would probably cut the opening with the largest holesaw I could get in and then cut between them to get a nice smooth arc at each end.

I guess you could cut cressents out of the subby to get the hoses through and then use halves of a piece of tube to in-fill and the fully gusset it to make sure strength is returned ... would probably be wise to box of the back of the front member of the subby ..... that piece cold then also be used to mount a front mounted rad!

Every day is a school day ...........

How fast and how expensive ...... the same question...

Be careful as that location would leave it vulnerable to stones and other road debris.

Feebs as your running jolt and a side rad there must be enough room behind the grill? Use a remote oil filter housing and that could free up a bit more space!

I agree with Joe about cutting the body work, It would be a shame to mess with it!

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1/4mile in 13.2sec @ 111 terminal on 15psi

Ive had a really good look though and there is room to run two boost pipes up between in front of the subframe and behind the front panel without cutting the subframe.

The front of the intercooler is black, and nearly the exaclt same size as a number plate. So its going to either have painted on white letters, or my 3D ones from my numberplate stuck on the front of the intercooler, it will look really good and stealth.

Previous Engine: 1040cc Morespeed engine, 1275 turbo head T2 Turbo Mirage Manifolds Megajolt
Previous engine: STD metro turbo, megajolt
Drives: 399bananahp (flywheel) Honda Civic Vtec b18c4 T28 Turbo 1968 Mini

Megajolt maps to download: http://www.jamesfawcett.co.uk/cms/index.ph...&gid=3&Itemid=3

Right ive just done a quick mock up in photoshop it only took 10 mins, this is what it will look like...



...I dont think ive ruined the look do you?

Previous Engine: 1040cc Morespeed engine, 1275 turbo head T2 Turbo Mirage Manifolds Megajolt
Previous engine: STD metro turbo, megajolt
Drives: 399bananahp (flywheel) Honda Civic Vtec b18c4 T28 Turbo 1968 Mini

Megajolt maps to download: http://www.jamesfawcett.co.uk/cms/index.ph...&gid=3&Itemid=3

Looks good febbs however I would be worried about damaging it and also how much you are reducing efficiency by covering up so much of the frontal area.

I did something similar in a Scirocco a few years back and ended up ripping it clean off on some nasty speed bump in West London when I lived there. Left me stranded at rush hour!!!!

But as I say, the look is cool.

Every day is a school day ...........

How fast and how expensive ...... the same question...

i wouldnt be overally happy with that location, plus you're covering a good chunk to start with the letters.

saying that it may work ok, depends on how much boost your putting through it to be honest as its pretty efficient as it is.

looks wise i think its spot on! i dont think you'd have much greaf with speedbumps or it being hit by anything much, f it works as well or aslong as you are gaining by fitting it, i'd go for it

SKYLINES ARE LIKE CLITS, EVERY FLANGE SEEMS TO HAVE ONE: see this sticker on my silvia

the Search-section on this forum is blummin superb & simple to use, unlike some other forums, without the search-section & the help of this bunch of chaps on here i'll never be able to !!!Start the day with a 998cc turbo!!! :) i'm getting closer though!

Tom Fenton says: I have it all, make me an offer

Hi,
I think it'll be ok there, paint the letters on so you don't obstruct the core.
Obviously it's very exposed there, but worst ways just by another cooler off ebay.....
I'm looking forward to see how this goes as I may do the same myself!
Cheers,
Gavin :)

Edited by Bat on 7th Feb, 2007.

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cool bat well ill get clear pictures and document it on here :)

Thanks for the advice from people about cutting with a holesaw first for smooth edges. Im going to do this, and then fit rubber sill trim too afterwards.

Painting on the letters sounds like a good idea, ill have a look and make a template and spray it on the rear of the intercooler first to see waht it looks like.

Yeah the intercooler was only £30 on eaby, and it had a embossed stainless thing on top which ive sold for £10 lol, so yeah its just the price of a new intercooler if it gets damaged by stones etc

Previous Engine: 1040cc Morespeed engine, 1275 turbo head T2 Turbo Mirage Manifolds Megajolt
Previous engine: STD metro turbo, megajolt
Drives: 399bananahp (flywheel) Honda Civic Vtec b18c4 T28 Turbo 1968 Mini

Megajolt maps to download: http://www.jamesfawcett.co.uk/cms/index.ph...&gid=3&Itemid=3

personally i woudnt do this idea feebs, its good but where are you gonna put your number plate when/if pc plod stops you and insists you ned a proper one? and i defo wouldnt be cutting any holes in the shell.

youve got megajolt right? so no dizzy? so why dont you work on either fitting a smaller alternator or repositioning yours that will leave you with more than enough room. if your not gonna run big boost surely you can use a smaller cooler and have it behind the grill.

no longer a series, but still 1.3 turbo.

get an rs turbo intercooler and be done

im sure you will be in the money if you sell this one and buy an rs turbo jobbie

i wouldnt want to cut it, im pretty sure that the subframe will end up in the way

As Carl says plod may get upset. If they do you could always hang the number plate infront of the grill for long enough to get the producer ticked off but that might be a real pain if they start to pull you daily (trust me, I know!)

I have to say I'm 100% with Carl and Nic on fitting the IC behind the grill after my experiences with the skyrocket.

Every day is a school day ...........

How fast and how expensive ...... the same question...

TD5 is the way to go for a behind the grill, efficient intercooler i reckon if you have megajolt.

Not gonna cut mine now, got talked out of it by too many people :)

for the topic tho, heres another mini thats cut out the front panel in the same place for an oil cooler http://www.minifinity.com/index.php?name=P...ewtopic&t=59267

Previous Engine: 1040cc Morespeed engine, 1275 turbo head T2 Turbo Mirage Manifolds Megajolt
Previous engine: STD metro turbo, megajolt
Drives: 399bananahp (flywheel) Honda Civic Vtec b18c4 T28 Turbo 1968 Mini

Megajolt maps to download: http://www.jamesfawcett.co.uk/cms/index.ph...&gid=3&Itemid=3

Hi,
I'm going to look into this soon, despite having shelled out of a new MPi front panel. Don't know if it'll be oil or intercooler though! I was thinking that as you'd need to modify the outlet position was to put smaller pipes on there which would ease installation slighty
Cheers,
Gavin :)

VEMs Authorised Installer / Re-seller. K head kits now available!

WB/EGT gauges. Click here for customers write-up

Visit www.doyouneedabrain.co.uk

My Mini build diary

TJ: roger, scirocco turbo? Was it an 8v with a turbo kit or something else?

And feebs, glad you're not cutting the car, it's too nice to mess with. As suggested, slap a RST one behind the grill. :)

Don't do it ....... will end in tears!!!!

Every day is a school day ...........

How fast and how expensive ...... the same question...