I got the tee from my local engineering supplies store, its a 5/8 barb straight thru with a 3/8 bsp branch, I "obtained" the valve from work, but any sort of valve will work, I used a metal ball valve so heat isnt an issue with it.

awesome, thanks for the sizes. I might head down to my local hardware store and see what they have in the plumbing section.

Well I just went as saw Bruce (my tuner), Im just going to leave it with him while i go on holiday. He's going to fit everything. Brackets, hoses, pipes, fittings, you name it, he's gonna do it.

I think its best he sorts it out. Its gonna cost more to do it this way but it will be the safest.

He said, he is going to fit it over the heat shield, but he also said, he will fit some special heat proof material that BA's use to help protect the core even more. He swears by it he reckons.

I have faith in his abilities, so Im gonna go with it.

Don't forget some after shots.

Aha now I see

Hi All,

Here's the next bit of my w2a setup....fitted an RS Liberty w2a radiator with a thermofan in front of the existing radiator last weekend.

It fits very easily on an AU, nothing is tight, except that one of the horns had to be removed (its plenty loud with one anyway).

Next step will be sorting some of the water plumbing bends, and mounting a little davies craig pump behind the driver's side headlight (busy in there as its also where my water injection fill point is!).

Looking forward to Shav getting back from hols to see pics and results from his setup...

Joe

Attachments:

File comment: RS Liberty W2A radiator + thermo fan in front of existing radiator Intercooler Radiator2.jpg [ 33.95 KiB | Viewed 3 times ]

Hi All,

Can anyone tell me if the attached pic of my davies craig water pump must be mounted the way its shown in the photo (ie. with the 'up' arrow up)? This will dicate where I can put it, and where my water hoses will run.

Thanks for the help!

Joe

Attachments:

Intercooler Pump Davies Craig.jpg [ 44.49 KiB | Viewed 1 time ]

Here are some more pics of some bits and pieces on my w2a setup. Intake (air) side is sorted, and almost have water side of things sorted. Will just need to mount pump, connect final hoses, then wire up. Can't wait!

Joe

Attachments:

Intercooler fill reservoir.jpg [ 53.74 KiB | Viewed 1 time ]

Intercooler core inside.jpg [ 35.61 KiB | Viewed 1 time ]

Intercooler Core Plumbing.jpg [ 58.8 KiB | Viewed 1 time ]

Intercooler core water in out.jpg [ 52.49 KiB | Viewed 1 time ]

Intercooler Core3.jpg [ 60.13 KiB | Viewed 1 time ]

Up means up. So i would mount as you have it in the pic. My carter pump has the same thing, albeit, different motor orientation. I would expect it to fail if operated upside down.

Just my 2c

Cheers

Daz

By looking at the pump itself the impeller configuration doesn't like getting wet as it's at the bottom of the electric motor. I'll replace it with a reliable submersible pump that's not fussy with orientation.

Slick, no I'll be sticking with this pump. Thanks Daz, I'll work out how it can be plumbed up to remain this way then.

Cheers,
Joe

like your setup Joe.

Hey fellas,

Just got the car back from Bruce.

Bruce wasnt at all enthusiastic about what had to be done to the car. He was getting to a point of giving up so he said. I must admit, when he did call me I though he torched the car as his manner over the phone was less than impressed.

I have mixed feelings of the results but overall I am happy.

I'll start with the bad points:
-He couldnt fit the thermo fan due to lack of room behind front bumper.
-He had to hack the top of the grille to get access to the heat exchanger.
-He couldnt get much more power out of the BP ultimate fuel.
-The 2.5" exhaust is now far too restrictive for more power.
-The smaller boost pulley has made the boost remain the same as before but this could be due to extra pipework that had to be added.
-I got slightly less power than I had expected. But I think that was due to restrictive exhaust.
-The injectors were at their max with the E85 tune.
-I have reached the maximum I can on an unopened motor.
-Its cost more than I wanted to get it all fitted

The positives:
-I reached my initial goal of getting over 200rwkw
-All the parts fit under the bonnet.
-The cooler core is cool to touch after a hard run
-Heaps easier to peel the tires now
-Heaps more response and torque
-No pinging at any temperature
-The engine feels stronger (could be a placebo effect)
-The water pump sounds silent when operating
-0-100kph times feels quicker
-Did I mention the torque??? Oh yeah, more torque definitely.

Run down of power outputs:
On BP Ultimate I got the best of 180rwkw (safe tune)
Remember a while back, I had the car tuned from Bruce for a dyno day last year and got the car tuned just for that day at a best of 194rwkw but that wasnt a fixed tune to the flash tuner. That was just for the dyno day. I only achieved a 194rwkw output after 2 runs on the dyno on a cold day. All other runs were risky with pinging evident. And that was the main reason why the tune wasnt a permanent one set to the flash tuner.

On a 60/40 blend of BP Ultimate and E85 fuel. I got the best of 205rwkw (safe tune)
One thing I noticed was the tractive effort torque had significantly increased.
Its not a mind blowing increase, but I was told the restriction was the cam and exhaust holding back decent numbers. Bruce had to spend a number of hours trying to extract as much power as possible but found it to be difficult due to the exhaust size and limited ability of the stock cam.

Refer to dyno print outs of before and after. If anyone can convert the tractive effort from the 205rwkw readout to Nm Id appreciate it.

Boost was kept to 9-10psi which was basically where it was prior to the intercooler being fitted. I figured due to the extra pipe work added and the smaller boost pulley being fitted it remained the same.

The pipework fromt he supercharger to the cooler is 2.5" mandrel as that is the opening size outlet that the supercharger has. There is a silicone reducer to connect the pipe with the 3" inlet of the cooler.

The pipework from the cooler to the TB is 3" mandrel.

I think having the 2.5" pipework initially has helped with the extra throttle response. This I found evident. Leaving the premises onto the main road, I found it easy as to light up the rear tires in first 2nd and 3rd gears. The torque is also noticeable.

Ultimately it is doing what its supposed to and that is to keep the intake temps cool as possible in degree any day. The extra power is a bonus. The lack of a thermo fan on the heat exchanger Im not sure how it will effect the water temps. Bruce reckons it shouldnt play too much of a problem when I get moving. Plus he reckons the twin thermos already on the car are already drawing air in while stationary anyway so it still is getting some air flow, just not from its own dedicated thermo. A good city drive will tell the story I guess.

Would I recommend this mod? In short, yes, but only with a 3" exhaust system and a cam to take advantage of the cooler air temps.

I'm in 2 minds as to whether I bother with the exhaust option at least of just enjoy it as is.


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Take the exhaust off at the extractors and go for a run around the block. If it makes much difference get the 3 inch done. It wouldnt take more than 30 minutes to check.