[Mk2] [Turbo] my Monster Chargecooler build! FINISHED!!

[jimGTS]

Interestingly I have a smaller 600bhp core but a bigger ST205 rad.

how thick is the st205 rad tho?
this rad is 2inchs thick.

[Super_red]

Interestingly I have a smaller 600bhp core but a bigger ST205 rad.

how thick is the st205 rad tho?
this rad is 2inchs thick.

Very true, considerably thinner I think its under an inch (25mm at the end caps probably, thinner core). I wish I had seen that rad on frozen boost before I finalised my order. There is a very similar one on ebay for £90 but it has a filler cap which will be hard to get to when the bumper is on.

[jimGTS]

Anything i found on uk eBay had the end tank pipes in random and unuseable positions plus not ideal sizes.
Obviously there was better options on US eBay.
But postage costs from US are crazy for something that size.

Hense why I went with frozenboost as I could order a ton of pipes, hoses, adpters and rad cap adater as well all in one go.

Granted it took bleeding ages to arrive! (and had £50 import charges). But hopefully werth it.

[jimGTS]

made some good progress today...
thankfully my 1/2 npt 90deg adapter turned up, woohoo!!


first up, how to support the pump, i needed to use the 2 a/c canister bolt holes in the bumper under the light to support it so i made a V shaped bracket. works ok i think.

next up supporting the rad, i hoped to keep a V shape between the rad and coolent rad, as heard this was ideal, so ended up drilling a couple of holes in a metal plate below the coolent rad to bolt the lower tabs and made some upper brackets to bolt into the horn holes to support the top (i need to put the horns back on yet, am sure theyll fit fine).

the 90 degree 1/2 npt adapter was my only choice as nothing would fit on the top rad outlet, super tight in that area, still i think it will work well and looks nice enough.

managed to sort the undertray out as well as best as i could.

[cvega666]

looks good man.

Do yourself a favour and get some black mesh for the bumper! Last stone that hit mine missed the CC rad by an inch, but I had to change the main radiator :>

[mark239]

unless that is armoured pipe I would get a conduit on those pipes going through to the front, or you will very quickly have a hole rubbed through them.

This one:

[jimGTS]

The plastic is cut there to allow some movement (lower left where the pipe touchs plastic, it's hidden)

I'll double check anyhow

[mark239]

just in case though - you don't want to be taking the bumper off! They'll also rub against each other.

[jimGTS]

doesnt seem like i got a huge amount done today, but getting close.

i cleaned up and painted the crush bar and rad brackets, as they did have a bit of surface rust.

bolted up the rad now along with the horn, wired in a relay for the pump to a switch so i can control the pump in the cabin.
(thanks to steve-o for guide to fitting the relay)

ive played around with the piping for the core and needed to remove the engine hook completely to run the pipes, so need to find a way to support the catchcan, no biggy.
i also cut off the bracket that holds the filler neck to give the core a bit more room, so need to reposition the filler neck also. probably more tricky, but hopefully not too hard to figure out.

now pipe positioning from core to tb, is actually WAY different to what i had planned and what i bought . i had planned, 135degree pipe from tb, 90 degree hose, 45degree pipe into core. this didnt work!!
looks like best bet for this setup is 90degree hose off tb, 45degree pipe, 45degree hose then straight pipe to core as per my pictures.

to join the turbo to core, i thought i needed a straight pipe, but due to angle of apexi pipe i got off NoddE and angle i have/need the core at, i just cut off a small rounded section of the 135degree ali pipe, as i no longer needed this given my new core/tb route.

so hopefully, all thats needed to purchase now is a 3inch 45 degree hose, a 2.75-3inch 90 degree reducer hose, and do a bit of pipe trimming and i should be good!!
(and figure a way to support the core!!!)
there is just about room for the intake hose off the turbo!

[Steve Horrocks]

[Driftlimits Performance]

your front undertray isn't gonna last long on them fittings!!

[jimGTS]

your front undertray isn't gonna last long on them fittings!!

Every other tray I could squeeze onto the oem tray holes, but those front 3 bolts just won't happen. It's too late to route the hoses differently, so maybe a suggestion as well??

[Driftlimits Performance]

penny washers!

[jimGTS]

penny washers!

That's what I have on there already.
Perhaps I could find larger ones.

[NoddE]

I see you are getting there
What are you saying, did the 120 apexi pipe not work? had to mod it?

[tarmac terrorist]

penny washers!

That's what I have on there already.
Perhaps I could find larger ones.

spacer tubes out of rubber bushes

[jimGTS]

not too much progress,

swapped in the more suitable rad adapter, so cut 180degrees of bends to only to 45degrees, so should help flow.

made some brackets to support the core, this nicely wedges it into the corner with some foam also to absorb any movement.

just need to get the tb to core pipe sorted, need a barb fitting in there for the EBC
also need a long hose to extend the intake pipe, as wouldnt quite work with the core in place.

aside from that, fill up, bleed, check for leak and pop the bumper back on.

[ashley]

Looking good Jim- the pipes on the rad look much better now, though I would be tempted to use something to stop them rubbing on the plastic you've run them through.

I'd also be tempted to make up a heat shield to help protect your cold pipe out of the cc from exhaust manifold heat. Have you got room to clock your turbo to run the hot pipe up and across instead of running it back and next to the cold pipe?

Excellent progress

[jimGTS]

Looking good Jim- the pipes on the rad look much better now, though I would be tempted to use something to stop them rubbing on the plastic you've run them through.

I'd also be tempted to make up a heat shield to help protect your cold pipe out of the cc from exhaust manifold heat. Have you got room to clock your turbo to run the hot pipe up and across instead of running it back and next to the cold pipe?

Excellent progress

I can't clock the turbo dude, it would touch the lid, let alone get a hose on there to.

Yeh I have a new heat shield to go on, no point using my old one as that was cut to go around my old ic pipes.

The rad pipes, I've cut enough away so it should be fine. Plus I've put some of that protective sleeve stuff on to. (out of view).

[ashley]

Yeah- thought it might be close on the engine lid!!

Nice one on the heat shield- I see you're one step ahead, good job sir