Hutchysrs50 the second - 'The project'

[hutchysrs50]

Intercooler.

This is the standard intercooler, it's a side mount intercooler (smic) and was removed from the driver side wheel arch.

I'm replacing it with the THS uprated intercooler, it's the seat sport style one but has uprated tanks, stronger welds and is thicker for better cooling

And a quick blury one in place... In the rain!

[Dark_Hero]

And in it's place...

[hutchysrs50]

Been updated already, and again in a second! :p

[Dark_Hero]

Awesome

[hutchysrs50]

Thanks

Fitted the timing bet etc then that night decided to buy a new camshaft with new bearings and uprated tappets :( doh!

[Dark_Hero]

D'oh. At least you get the experience of taking it apart

[hutchysrs50]

Yep, again.

Will take plenty of pictures as usual!

[hutchysrs50]

Small progress today, had to alter the turbo housing more to avoid the driveshaft hitting it. Pain in the arss when fitted to the car, also the small bolt was hitting the oil return pipe so had to be alterd slightly as well!

[hutchysrs50]

Jabba sport cone in the box

With most of the engine bay going back together I started putting some of the basics back in, upgrading where I can.

Standard air filter on the left, about 5k miles old and a jabbasport cone filter on the right, designed to go into the standard airbox. Cleaned the cone filter with proper green cotton cleaner and warm water and blew it out with the air line before fitting. I also cleaned out the air filter box while it was out of the car, washed the inside and again blew it out with the air hose.

[hutchysrs50]

Pd 160 intake

With the air filter in place, I thought about time I upgraded to the pd160 intake, the cold air feed from the seat ibiza cupra model. Some say it makes improvements, others say it's just witchcraft! Either way I take it as an upgrade from standard so changed it.

Bigger intake on the left, standard intake on the right.

[hutchysrs50]

Darkside turbo intake pipe

I imagine this is more for 'show than go' but the theory behind it is good. Will stop the airbox being sucked towards the engine, as well as being bigger and smoother for a faster air intake.

Oh and looks great in the engine bay.

[hutchysrs50]

Small update I guess. All the silicone joins I need have been deliverd as well as a few other things I've bought.

My bad back is still stopping me from doing any more of the work so no progress on the car yet.

[hutchysrs50]

Intercooler brackets turned up on Wednesday which was a great suprise being on back order for such a long time!

[hutchysrs50]

It's been put together to run as I need the car for the next four days and then will be stripped back again (partly)

Only picture I took almost finished.

[Toxicvrs]

Did that bolt come off in ththe end?

[hutchysrs50]

Which one again sorry?

[Toxicvrs]

Which one again sorry?

Was it an Octy drop link?

[hutchysrs50]

Wrong thread I think mate

[Toxicvrs]

Wrong thread I think mate

Ohh c*** yeah.

[Dark_Hero]

Where does your catch can run to? It's got the inlet, a vent and another pipe leading to the front?

[hutchysrs50]

The pipe going along the front towards the alternator goes down to atmosphere, not that anything comes out of it, you get very light smoke sometimes from the filter but that's about it.

I wanted minimal pressure in the crank case so wanted a can with two outlets and one inlet. I thought about it for a while with running it back into the turbo intake pipe but didn't want to risk any build up of oil in the can being drawn out the tank and back into the turbo. I also didn't want the filter being used to suck air into the engine either as it's after the maf etc and wouldn't be regulated.

I'm happy with how it is for now and think I have the best of both worlds anyway.

[Dark_Hero]

You'll probably notice the vapours more with the colder damper weather coming in. I've tried a couple of set ups and for now have just returned it to stock

[hutchysrs50]

That's my worry!

When I was getting some pipes welded I almost! Got the blank on the turbo intake pipe welded over but thought I best leave it for now incase I ever change it back, a bung and some very bling red tape got out around it for now

[hutchysrs50]

Took the bumper back off to check all the joins and put some proper hoses on. I had loads of mikalor clamps left over so ended up putting two on almost every join just to be sure!

Apologise for the messy unit

[tommccabevRS]

Really good read this mate well done. Wish I had the knowledge to do stuff like this I'm kinda stuck at fitting Coilovers and brakes ha.