Intercooler fitting
Turbo Mini Forums

With the rr session provisionally booked for next tuesday, I decided to fit one of the many intercoolers i've been collecting.

JF supplied the modded pipes (would have loved one of nic's plenums, but cash is a major issue at the moment, and for the money, JF's pipes are hard to beat)

Ordered the silicone hoses from zenaracing and got 2m of stainless tube from the local motor factors.

After a morning of angle grinding and fannying about, here is the result:



Not the best location ever, but not bad with the limited amount of silicone pipe i had.

I really struggled to get the motivation to do this as I thought it was going to take ages, but was actually pretty simple. Given the amount of How To intercooler requests recently here is a list of the bits i used:

series 2 escort intercooler
JF plenum pipes (contact giallofly on here for them)
Silicone hoses from zena:
2 x 51mm 90 degree elbows
2 x 51mm 3" straight couplers
1 x 51mm 45 degree elbow

2" steel exhaust pipe cut in to the following sizes:
300mm
250mm
110mm

10 x size 3 jubilee clips

Hopefully this will be of help to someone. :)

Good to see you've got back into the garage mate! :)

Looking good. If you don't mind cutting a hole in your bonnet, I recon you could fit a 90 degree elbow where the 45 is and the 45 where the coupler on the cooler inlet is, the coupler on the cooler outlet and you'd be able to get it sitting derictly in the airflow and only need one extra 90 degree hose and a 300mm or so piece of steel tube. And I recon you'd have a damn good cooler setup especially if you seal it in like Robert did!

Could be worth a few extra nanas?

Edited by matty on 12th Apr, 2008.

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

Very nice mate! Helpfull aswell, cheers

looking good dude

Is it going ok now?

hmm, sort of. Needs setting up so badly. It misses and pinks if the boost goes over 6psi, so i've wound the bleed valve right in.

There is still so much i want and need to do to it, newquay may be a struggle but i'm determined to make it happen!

Is yours back together again now?

Glad your getting there now. I hope an RR will sort it out for you.

Best 1/4 mile 13.2 seconds @116 mph
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cheers bud. RR was really useful, although it's thrown up a few things I need to look at fairly quickly.

Need to sort a proper clutch setup, the standard verto one is useless and I've already PM'd Mr. Benross about a head.

Oh yeah, it made 114.1bhp at 5500rpm at about 7-8psi aparently. I think that might be a slight over estimate unless my boost gauge is reading wrong. But it's tons better now, stuart gurr was really helpful. :)

slight update, my addition 90 degree elbow finally arrived so have fitted up the cooler as per matt description.

Looks tons better imho and will obviously be a lot more efficient.





Last weekend i also fitted an uprated 8psi actuator as the standard one was goosed and opening at about 2.5psi and wasn't holding boost when i bled it.

Had been good as gold for a few days on 8psi, but today the clutch has started slipping like a bastard. :(

can you slacken the pre load for newquay?

Have you got any pre verto bits at all??

Nice one, that looks MUCH better. Have you noticed any difference with pinking?

I know Mr Weston has a near complete pre verto setup that is lying around his garage, apart from a back plate. Im sure he could be convinced to part with it!

Could be a late one Thurday night! :)

Edited by matty on 27th Apr, 2008.

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

I don't have any pre verto bits at all, but I'd be well up for a road trip to collect some!

I'm guessing it's an engine out job, which could be an issue as i don't have a crane.

oh yeah, and it doesn't pink at all at the moment - well not on 8psi anyway.

And yes, will have a go at winding the preload in a bit, absolutely paranoid about losing the little circlip thing though!!

Hi,
Just don't use so much right foot, easier than adjusting the actuator.
You can change the clutch with the engine in too :)
Cheers,
Gavin :)

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Clutch isn't too much of a problem mate, if you can get the parts altogether then I don't mind coming over to lend a hand.

Is it definitely adjusted correctly?

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

Hi,
Nothing to adjust on a verto that would stop it slipping :(
Cheers,
Gavin :)

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Does anyone have a spare clutch arm?

ive got a grey diaphram and old plate lying about, im sure i must have a flywheel and back plate too somewhere

Bat, I don't think i can be trusted! As soon as a new mini tries to overtake my clutch will be in pieces!

Have been looking through the various haynes manuals and it looks a bastard to do in the car, but i'm up for a challenge.

I can order bits from min-its on monday that should be here for wednesday... could be a tight one!

Matt, thanks for the offer, if you are free at some point that would be hugely appriciated... have you got a spare k1000 head you can bring too?

They're not too bad to be honest mate, the hardest part is usually getting the old one off. After that its quite easy...he says...lol

I'll try and dig out a spare K head, if we get a spare hour we may aswell chuck that on too for good measure.

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

When is a good time for you?

I suppose Wednesday or Thursday as you need to get parts! If I hack it over straight after work we should have some decent light to work in.

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

ric ive got a pre verto flywheel, friction plate and what i believe is an orange diaphram that you are welcome to but i dont have a back plate. i'll dig them out just in case.

cheers ian. :)

Going to order bits from min-its today. What starter do i need for that flywheel, a pre engaged or an innercia(sp)?

Also, can i keep the same clutch housing? I take it i will need to buy a new bell housing and slave cylinder though?

Sorry for all the questions...

keep the same wok and clutch housing, you'll need an inertia starter motor.

if you've already got the flywheel/backplate/friction plate/diaphragm then you'll need to order from minits:

pre-verto arm
plunger
release bearing
slave
hose
might aswell get new clevis pins for good measure too.

i dont have a backplate so you will need one of those aswell unless you can get one off someone else.

does anyone know how to identify what spec diaphrams are? i know they usually come with a little coloured paint mark but the spare one i have doesnt seem to have any mark but i was led to believe it was an orange when i bought the car. i used it on my original engine for a while and dont remember it slipping on normal-ish boost so should be alright anyway Ric.

By measuring the spring thickness you can equate this back to which it is, the info is on the forum somewhere but I've just had a quick look and couldn't find it.