PRE RADIATOR

[MANDALAY]

New here . Thought ild show you how i ,ounted my preradiator for my A.W intercooler for my SC ROTREX set up.
I bought it from Rogue so close to your side of the world. Couple of mods as our AC set up is a bit different
Well its been a year since i made these brackets and bought my A/W intercooler radiator from Rogue. Thought ild show you how i set it up

THE BRACKETS


BUMPER OFF SHOWING THE AIR CONDITIONER RADIATOR


CLOSE UP WHERE THE BRACKET WILL BE.
See those 2 little screws , they hold the guts of the radiator and go all the way through . In actual fact they have still about 5 mm of travel on the back My brackets are 4 mm thick with the section where the screw is rebated down to 2 mm


BRACKET IN PLACE


BRACKET IN PLACE OTHER SIDE


A/W RADIATOR IN PLACE MINUS THE HORNS


DONE Now have to wait till new year so as i can get some hoses made

[MANDALAY]

Installation of the Bosch water pump for my A/W intercooler set up.
It sits just in front of or windscreen water bottle
Used all stainless steel bolts. The bracket itself is cushioned with rubber feet to dampen the pump from the chassis
You can see the 90 degree entry hose from my aluminium pipes. The exit hose to the radiator wont happen for a few weeks , Its all drawn but they are very busy designing Fords next model hoses .

[MANDALAY]

Here is a picture of the bottom of my car with the trays removed.
Pretty busy under there with little room to add 2 19 mm aluminium/ copper pipes for my A/W set up.
I could have run them outside the covers but dont like that idea, so the only option is to make new trays with a bump for the 2 pipes.
After thinking about this for a while i came up with this method.
Firstly to make moulds of the plastic trays , good idea but with one problem , they are flimsy and would move and wont mount in the right location( been there done that many years ago )
So what i did was to mount L shaped made brackets to all the mounting holes,
them bog pieces of MDF to these brackets and join them all together,
That way i would have a jig of the bottom of the car.
The trays would be mounted to this jig. This way there wont be any movement and all the locations would be spot on.
To simplify things i pop rivited 3 of the parts so as to make one part.
So the next step is to make the mould. I used 2 part epoxy and HEAVY carbon fibre. I laminated 4 layers as to make a very strong rigid mould.
Once i clean up the mould ill add the tunnel for the 2 pipes. Once done i can finally make the finished article. When i have time ill make the other panels the same way.

[MANDALAY]

Here is the mould made.
Now i can make the finished article . Finally !

[MANDALAY]

Aluminium piping for my A/W intercooler set up.
From the front to the back.
Pic 1 from the air con expander tank side. This is also where the FERRARI compressor and air horns will be located
Pic 2 the other side where the Bosch water pump will be located
Pic 3 passing the frunk
Then hose couplings to the section that runs underneath the fuel tank
Pic 4 and 5 under the fuel tank
Pic 6 coming into the engine compartment. Bends near the engine mount then clears the factory hoses and gear box links
Pic 7 showing wgere it exits.
Hoses then connect it the the aluminium pipes connected to the engine. Needed to make sure i cleared the air box , resonators , hoses and the final location for my oil catch can

[MANDALAY]

This is the bracket to hold the coolant for the A/W intercooler set up.
I also put a bracket over the nipples that holds on the braket to eliminate any chance of bending.
Also pics as it sits in my car.
The shape of this 85 corolla water bottle is great

[RST]

Hey Mandalay!!!

Welcome to the club.

....Guys you might not realise this but you're looking at one of the most obsessive / well thought out MR2 installs on the planet here. Superb installation with absolutely no shortcuts taken!

[phipck]

indeed! i can tell by the use of carbon weave for a mould when most would use fibreglass!

awsome progress and interesting reading

[Andy F]

That car is like brand new!!!

Great work too

All you need now is turbo

[Moo]

That's a very impressive piece of work

[MANDALAY]

Hey Mandalay!!!

Welcome to the club.

....Guys you might not realise this but you're looking at one of the most obsessive / well thought out MR2 installs on the planet here. Superb installation with absolutely no shortcuts taken!

Thanks buddy.
Thought ild post this section of my build here as i used a Rogue part.
Im sure some members of this forum have followed my build.
If not nudge me and ill update everyone with my build. Glad to share information............

[Rev 3 Kris]

what can i say the workmanship on your car is amazing !!
How far you away from finishing the car ?

[MANDALAY]

Well right now the engine is nearly put together, I am waiting for the SC pulley upgrade to be machined. Should be in the car by first or second week of March. Then connect everything and off to the tuners. Hopefully ill be driving her by end of March

[MANDALAY]

URL=http://img706.imageshack.us/i/dscf6116y.jpg/][/URL]

[asdrewq]

Awesome craftmanship especially the undertray, and the cleanest mr2 i've ever seen