ducted FMIC

i've almost finished my FMIC ducting project but run out of time for the moment. the ducting has made a considerable difference to how the air flows through the front. if you put your hand infront of the IC you can feel the draw from the stock fan behind the rad, which wasn't present before.

i was in two minds whether to mount the IC at a (vertical) angle so i thought i would try the most streamlined option first and mounted it at 90deg. it is showing no signs of needing any more help with the contact area, so i think it will be staying like that.

the IC is a HKS S-type (the small one) i can't see any need for anything any larger apart from ridiculous cars, it's nice and light and helps to keep the turbo to throttle volume down. air temps are superb off boost and at sustained 1.6bar they are still steady.

i used some thin aluminium sheets from B&Q for the construction, self threading screws, some small nuts and bolts, some hi modulus automotive sealant and a few pop rivets. the whole thing is super light.

the first job was to seal the front top of the IC to the crash bar. this sheet ends in a 45deg angle to help the air flow up to the rest of the rad behind. you can see the 2 pieces of metal that apply pressure to the sheet to keep it in contact with the IC top rater than fastening with anything that may cause a leak. it is also sealed.

The next job was to seal the sides where air escapes under the lights. The options are running out for where that airflow is going.

Next was the trick part, getting it to seal underneath with the stock front tray. I cut the stock undertray to allow this custom box to go in place. This seals in the sides and bottom of the IC. It tucks up behind the rubber lip on the stock nose but I can’t help thinking it needs extending out to join with that lip to make a smoother front end.

The last part I made was an FMIC panel to seal the flow of air to the rad. It’s hand cut and needs a bit of paint or a polish. it is super light, non of this cast iron stuff

Ive also made a mockup side panel to go on, but this I where I ran out of time. I’ll enclose some pics of it but i’m not sure if I need to add this part

**pics later**

aw, isn't she lovely?

That's a lot of hard graft.

What did you use to cut the metal sheet, snips?

That looks neat, have you done any high speed testing with the front undertray in place yet??

That's a lot of hard graft.

 

What did you use to cut the metal sheet, snips?

snips, dremmel and a big hand guilotine, you know the type that used to young kids hands off at school

Geezzus

You 'da man!

That looks like a really good job...very inspirational.

Can you post a tool and equipment list please.

have you done any high speed testing with the front undertray in place yet??

yep, in my own private wind tunnel

i went to some lengths to add strength where needed. any pop rivets have a steel washer behind them and all bolted areas have double washers the final one being quite large. it's stronger then the rear plasic undertray. it won't take kindly to being grounded though.

Very nice mate, gotta beat it now

So what does the i/c look like?

I did an 80% ducting job in about 2 hours with plasticard

Bangs-per-buck, that's me!

Very nice job though, good work fella.

-Ian

That looks very thorough indeed and very tidy too.

I also ducted my s-type recently using the same stuff but only ducted the front of the fmic to force all the air through it, but didn't seal between the fmic and rad.

sorry for the hijack eyefi, but you're on stock 16s arent you?

sorry for the hijack eyefi, but you're on stock 16s arent you?

stock 17's mate

Very nice mate, gotta beat it now

the car or the ducting? i'd like to see how it does against a similar car.

I did an 80% ducting job in about 2 hours with plasticard

 

Bangs-per-buck, that's me!

 

Very nice job though, good work fella.

 

-Ian

could you fit the front undertray on?

So what does the i/c look like?

a big shiney radiator

i'll dig out a pic.

nice job .... this is what you do with your spare time then , no wonder i never see the car on the road !!!!!!!!!!!!... i am thinking about doing the same thing in the winter ..now all we need is something to keep the engine cool .. so get on the case ..........well done

Very good mate Was thinking about doing this myself but wasn't sure how to cut it. May take a trip down B&Q tomorrow

nice job , but someones nicked your spoiler and wheel caps

nice job , but someones nicked your spoiler and wheel caps

swines! :littled:

intercooler for john.

i'm still waiting on some new fasteners for the top part of the scoop.