jevansio Posted September 17, 2009 Share Posted September 17, 2009 Thought I'd document the ducting I'm doing to my FMIC. The last time I did this was to my 4" deep XS-Power cooler here (http://www.mkivsupra.net/vbb/showthread.php?t=127740). I've since replaced that with a 5" deep Greddy 4-Row, and the ducting I made doesn't fit. Thought I'd make a better job this time, it was made in 4 parts last time & didn't totally cover the FMIC. This time the plan is to make a frame that attaches to the FMIC & the bumper, then use 4 pieces of aluminium sheet to cover the 4 sides. 1st up I made this frame which will attach to the FMIC. The edges are wider at the top & bottom so it slots over the cooler, I'll figure a way of attaching it later (probably drilling carefull into the coolers top & bottom plates & using some very small bolts). I was half way through making the frame that will attach to the bumper when my rivet gun strangly stopped working????? Hopefully I'll get more time/good weather this weekend to make some more progress. Quote Link to comment Share on other sites More sharing options...
Kirk Posted September 17, 2009 Share Posted September 17, 2009 subscribed always enjoy your install threads! gives me ideas for mine Quote Link to comment Share on other sites More sharing options...
Stealth-1JZ Posted September 17, 2009 Share Posted September 17, 2009 subscribed aswell Quote Link to comment Share on other sites More sharing options...
JamieP Posted September 17, 2009 Share Posted September 17, 2009 Nice one, this is on my list of things to do this winter. Quote Link to comment Share on other sites More sharing options...
markssupra Posted September 17, 2009 Share Posted September 17, 2009 I spent hours ducting my frontmount and mounting it tight to my bumper, worth the effort. Quote Link to comment Share on other sites More sharing options...
SUPRAPAUL Posted September 17, 2009 Share Posted September 17, 2009 subscribed as well, still need to get cracking fitting my fmic hopeful this thread will get me motivated to get cracking lol Quote Link to comment Share on other sites More sharing options...
dandan Posted September 18, 2009 Share Posted September 18, 2009 I spent hours ducting my frontmount and mounting it tight to my bumper, worth the effort. Me too - I think it actually spilled into day and days and days Quote Link to comment Share on other sites More sharing options...
paul_h Posted September 18, 2009 Share Posted September 18, 2009 not having a dig at all, i am actually curious as to how this works? looking at the pics in your previous thread how dows it force more air through the intercooler? wouldnt it just stop less air getting into the areas to the sides rather than forcing it to go through the cooler? Quote Link to comment Share on other sites More sharing options...
mwilkinson Posted September 18, 2009 Share Posted September 18, 2009 not having a dig at all, i am actually curious as to how this works? looking at the pics in your previous thread how dows it force more air through the intercooler? wouldnt it just stop less air getting into the areas to the sides rather than forcing it to go through the cooler? Air will always follow the path of least resistance. Thus if the sides of the intercooler are left open the air will move around the intercooler instead of going through it. It's debateable as to how much ducting improves the performance, but the science and theory seems sound. Why not try and maximise the potential of any piece of performance equipment. Toyota ducted the original SMIC!! Quote Link to comment Share on other sites More sharing options...
jevansio Posted September 18, 2009 Author Share Posted September 18, 2009 Nearly every cooler / radiator I've seen on a performance car (& many non) have been ducted in some way, me & Michel did some tests a while back on my ducted XS Power intercooler vs his unducted Greddy 4 Row, my inlet temps were cooler, not a great comparison I know but hopefully this ducting will be easy to remove so I'll get some back to back results on this car when it's running again. Tonight I completed the frame that goes around the bumpers mouth. I used 2 L shaped pieces here, mainly to prevent making 2 brackets Pics of both pieces positioned on the car. Tomorrow I'll make some brackets to hold both pieces in position WRT each other, then I can begin making the 4 card templates that I'll use to make the aluminium sheets that will make the 4 "sides" of the ducting. Quote Link to comment Share on other sites More sharing options...
themodifiedkid Posted September 18, 2009 Share Posted September 18, 2009 Work of art mate, well thought out that. I followed the tread on your xs power fmic and looked spot on so im sure this will be identical. Nice one Quote Link to comment Share on other sites More sharing options...
michel lane Posted September 18, 2009 Share Posted September 18, 2009 looks great jay .. iam going down to B&Q tomorrow. Quote Link to comment Share on other sites More sharing options...
jevansio Posted September 19, 2009 Author Share Posted September 19, 2009 I cracked on today, zipped the 2 pieces together so I could check I'd correctly marked how they should sit in relation to each other. I then cut a card template for the top side. I used 2 pieces of wood to space the frames apart, again just zipped to hold in position as the outer panels will be enough to hold the shape once the wood is removed. Here's a piece of sheet aluminium cut to shape with tabs. And the top section rivited in place. To finish all I need to do is the other 3 sides. I'd kinda decided I would ditch the frame around the bumper, this aluminium sheet is pretty thick & strong & the frame wouldn't add anything. Funny thing is I think I'm going to ditch this attepmt & have another go. Don't get me wrong, it would work perfectly, but it's too snug a fit on the bumper which will make taking it on/off a pain. Just gotta decide what I'm going to make the next one out of, don't think I'm going with the frame approach, will make it out of something such that the 4 sides along make the structure. I'll be back Quote Link to comment Share on other sites More sharing options...
Kirk Posted September 19, 2009 Share Posted September 19, 2009 (edited) mate you impress me more and more! great work but why ditch this approach, the sheet of ally seems a realy good idea working like a scoop impressive pile of bolts you have.. weee bits? Edited September 19, 2009 by Kirk (see edit history) Quote Link to comment Share on other sites More sharing options...
Andy-No-Knee Posted September 19, 2009 Share Posted September 19, 2009 Subcribed.... Quote Link to comment Share on other sites More sharing options...
jevansio Posted September 19, 2009 Author Share Posted September 19, 2009 mate you impress me more and more! great work but why ditch this approach, the sheet of ally seems a realy good idea working like a scoop impressive pile of bolts you have.. weee bits? Cheers I think I can make a better, lighter, more elegant design. I don't like the way I've bent the tabs, they look all wavey Quote Link to comment Share on other sites More sharing options...
jevansio Posted September 20, 2009 Author Share Posted September 20, 2009 (edited) Started attempt no 2 this afternoon, just uploaded the pics (I'm just popping out for a chinese, will add text when I come back) Looking at the pics doesn't actually need any words, it's pretty self explainatory. The bends are a lot shorter than the 1st attempt so are a lot neater, I just need to make some tabs to attach it onto the cooler then it's job done I might add some more rivets (as you can see where there's only one the bracket can swivel), and maybe cut the brackets so they don't stick past the ducting. Edited September 20, 2009 by jevansio (see edit history) Quote Link to comment Share on other sites More sharing options...
Kirk Posted September 20, 2009 Share Posted September 20, 2009 like cutting up sheets of ali dont you another good outcome, looks very functional. Sticking with this 1? Quote Link to comment Share on other sites More sharing options...
jevansio Posted September 20, 2009 Author Share Posted September 20, 2009 like cutting up sheets of ali dont you another good outcome, looks very functional. Sticking with this 1? My hands are covered in little nicks now Yeah, I'm happy with this, it's solid, simple & should work a treat Quote Link to comment Share on other sites More sharing options...
AndyT Posted September 20, 2009 Share Posted September 20, 2009 Lovely job Jay. I have nothing but respect for people who take this sort of work on personally. Probably 'cos I'm cack at it. Quote Link to comment Share on other sites More sharing options...
SteveR Posted September 20, 2009 Share Posted September 20, 2009 Nicely done. Quote Link to comment Share on other sites More sharing options...
Kev_A Posted September 20, 2009 Share Posted September 20, 2009 Jay, do the edges of the duct meet perfectly with the front bumper? How did you figure out the size of the gap? or was it trial and error? Really inspired by your design and would love to have a go myself, is it something you can achieve with "regular" tools, a sheet of aluminium and some brackets? Quote Link to comment Share on other sites More sharing options...
jevansio Posted September 20, 2009 Author Share Posted September 20, 2009 Cheers chaps Kev, it doesn't meet exactly with the front bumper, mainly due to ease of fitting the bumper. I pretty much just measured to get the size, but the card templates helped prove everything was OK. Defo can be done with basic tools, a rivet gun & tin snips would help. If you want any help, or just wanna pop over to have a look you're more than welcome Quote Link to comment Share on other sites More sharing options...
Kev_A Posted September 20, 2009 Share Posted September 20, 2009 I might just do that one night mate (when my lass is at work and takes my collar off that is ) Really wanting to do this as for starters I trimmed my front bumper "Mouth" back a little as it was fouling the I/C, trimmed it a little too much Where did you get the aluminium and brackets? Quote Link to comment Share on other sites More sharing options...
jevansio Posted September 20, 2009 Author Share Posted September 20, 2009 I trimmed my mouth back a bit too I got the aluminium sheet off ebay & the brackets are just angle bar from B&Q Quote Link to comment Share on other sites More sharing options...
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