[s-cars] Cheap/effective FMIC option w/ Sex and free beer

[Pat Martin]

It would be easy enough for hap to test Corky's theory regarding face area.
Just ask him to make a boost run with his bumper holes open and then have
him test it with them covered with masking tape.  I for one would be
interested in seeing the numbers.

It might save you hacking into your bumper.

Pat Martin
95 S6 Avant, IA Stage III, 18x8 RS knockoffs. 255/30/18 PZero Nero's, Back
in the stable again.

86 4kcsq turbo, 3" "cat" back, Coil overs/konis holding it up, MC and loving
it.  Custom ECU with data logging tuning it, Drilled and stopping it.
Borbet's with Kuhmo V710's  turning it,  K&N and uh....

98 A6q Avant.

97 Ford F350 Crew cab, 4x4, GGGGGAAAAAASSSSS.  Never met a station it didn't
like.  

-----Original Message-----
From: s-car-list-bounces at audifans.com
[mailto:s-car-list-bounces at audifans.com] On Behalf Of lschip at speakeasy.net
Sent: Sunday, March 05, 2006 5:25 PM
To: gcmschemist at gmail.com
Cc: s-car-list at audifans.com
Subject: Re: [s-cars] Cheap/effective FMIC option w/ Sex and free beer

Eric,
I helped Brian P. with his FMIC, moving the steering cooler
and such.
There will be a complete write-up on this someday, but
to answer a few questions:
1. We didn't want to weld directly to the pipe connections
on the intercooler, but to fit the pipes behind the bumper
cover we needed 45deg immediately off the IC, and we didn't have any
2.5" 45deg hoses. That would have been nice (Brian wasn't able
to find any 2.5" 45deg hoses, in time).

2. You might be able to do all the piping with alum. pipe
bends and hoses, but you'd end up with a lot of hose connections;
and more places for leaks. Fitting the pipes and welding is the
better solution. Or get SAMCO or other to make some custom
sicone hoses (do Si hoses baloon enough under boost to cause
even worse lag?)

3. We had to build up the 2.5" alum pipe to an OD of 2.75 to fit
the turbo outlet hose. Dunno why Audi did this, and it was
a PITA for a beginner welder. We rolled up a piece of sheet AL
into a tube of 2.75" OD, cut slits in that and bent in to 
the 2.5" pipe and welded it enough so I could smooth it with
a die grinder (it sounds easy enough...)

4. We welded angle pieces to the IC mounting tabs because I
wasn't confident that drilled/tapped tabs for the brackets would
be strong enough, long term. I liked bolting through the angles.

5. We didn't cut any of the bumper and only a small amount of
the lower bumper cover supports (the vertical pieces that hold 
the small lower grills - you can't really even see where we cut).

6.Yes, about 1/2 the IC is blocked by the bumper. It might work 
better if some ventilation was provided through the bumper (I think
I've seen photos of this? Maybe Hap's car?). But Brian has already
seen higher boost pressures with the bumper covering it; in Denver
in winter. Maybe hot summers will require more airflow over the IC.

As Brian said, we could do another in a lot less time; maybe less than
1 day. 
We spent way too much time test fitting the IC locations, using PVC 
pipe to check clearances, and fine-tuning the AL pipes before welding. 
Oh, and basically learning to TIG weld.

I'm happy to answer any more questions.

Chip





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