intercooler problem mod

Is biggamehunter still on here? If so can he pm me about this mod? I need some advice on the mounting of the sensor in the ally pipe. Ta.

neat looking mod in o.p.

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http://www.demon-tweeks.co.uk/motorsport/hose-joiners

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this place be just down the road ..

http://www.auto-performance.co.uk

starting to see potential hole in wallet ;-/

ok .. some added data / info ..

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1 .. copy paste job from another thread .. :

this came up on a recent google search ..

http://www.easyperformance.com/support/technology-papers/cai-system-design-consideration-primer

Introduction :

" Before one can set forth to design a good air filtration and induction system, the function of a good system must be explored. A good induction system on any engine must address the following aspects: air filtration, airflow dynamics and thermodynamic properties. The bottom line goal of the induction system is to deliver the highest density air in the greatest volume to the engine "

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2 .. how mine ended up for now .. ugly but quite functional

also later .. ..
added some insulation around the temp. sensor housing
insulation be 10mm closed cell .. around the alloy tubing bits
'gorilla' tape secures the insulation material
and .. heat reflective tape over that ..
90 deg. alloy lost out with the h.reflective tape
and made do with elec. insulation tape ..

in terms of heat .. measured on surface with an i.r. thermometer
( prior to adding insulation )
bare alloy tubes were the hottest
a.i.t. housing in middle ( so same plastic as the factory air-intake )
coolest were the silicone hoses ..

aim to insulate the intercooler hose leading to the a.i.t. sensor housing .. someday ..

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will post list of bits that i used at some stage
measurements be on this comp. .. somewhere
( yeah .. opted to leave the pre sensor i.hose as is
( 'n not replace it with alloy tubing ..

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as for result .. the added drive-ability that i were hoping for
plus .. only 1 clip to undo to when taking off off the air-filter housing ..

( n'other Edit ) ..
only 'issue' at first were the connection to the air-filter housing ..
it would come apart due to engine movement ..
and partly cause the first clip were unfit-for-purpose ..
refitted with a better clip .. and added some rubber block buffers
between the air-intake and intercooler ducting ..
thus preventing the air-filter intake hose bit from moving forward ..

ideally .. could do with a cylindrical air filter in there .. somewhere ..
to do away with that effing annoying air-filter cover ..
and it's re-fitting .. partic. that 1 lh.side back bolt ... i does hate it !

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EDIT to add .................

from notes found on this comp.
( as the mod. was done this past summer )

my measurements were .. inside diameters
( original plastic-ducting unit outside measurements )
intercooler .. 51 mm
air intake .... 70 mm
egr 'delete'.. 57 mm

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ended up getting these bits ..

intercooler part .. :

180 degree silicone ( in 57 mm )
250mm straight silicone ( in 51 mm )
400mm straight alloy

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pre air-filter part .. :

i chose 70 mm ..

45 deg. silicone
90 deg. alloy
250 mm straight silicone
500 mm straight alloy

and .. the alloy tubes must have end beading on them
( a must .. for the intercooler part )


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the missing pic from page 1 :
BGH's intake mod.

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rekon DD's mod needs posting here
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