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  #1  
Old 16-03-2014, 08:45 PM
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Default FMIC/OC fitting The stealth look! - Ginola's Project thread

As many of you know I have been quietly hoarding parts in various sheds and cupboards for the last few months, much to Handbrakes dismay. Well with the Glorious weather I couldn't have had better luck (other than Handbrake's back going which reduced my coffee supply)!

Lets hope it all works OK! *(puts his giant bag of zip ties down!)

I went about removing the front bumper and taking some basic measurements, hard to do as the HDI kit instructions are for a previous version of the kit and don't represent the kit supplied fully.. so mounting points where different.



Big thanks to CJ who popped by and helped finish chopping the bumper Iron and working out where the 7 different pipes went! The core is lightly dusted black with some manifold paint! should cope with heat/chips OK I hope.



I used a bit of silicon pipe for some elaborate beading..



After sizing the bumper up I came to the conclusion that the core was sitting too low and took a stab at moving and re-trimming the bumper Iron,



Looked a bit neater and pipes all seemed to fit a bit more snugly...measure 5 times Dave!!!)..

Next day...

First things first, I needed to mount the oil cooler. Using a Mocal mounting kit, I chopped it down and sprayed black, using existing holes kindly supplied by Subaru normally used for cable tie holes for fog light leads and air-bag sensor wires, added some silicon hose chopped down for vibration damping. Thank you Karting Steve for the inspiration for the fitment location.


Ok time to trim the bumper! This was a bit scary, although I set about doing it with an angle grinder to start with I switched to a Dremel in the end for a neater cut in the tight spaces.. I think I must have sized this up about 15 times, and spent ALOT of time changing Dremel blades! I also had to make a small adjustment to the intercooler core position when I started running out of bumper to cut!! once the position was set I trimmed and re-drilled the mounting brackets for the lower zunsport grill (this is a stealth install after all!)

Starting to look decent!


Sunday dawned and only had a few jobs left to do.. Sorting the cold air feed for the intake and making sure everything was clipped and trimmed back in place where it should be.
I managed to get hold of a large rubber snorkel that just so happens to be the exact same size as the intake on the STI front fog cover!! this cant be known to anyone otherwise the price would have been 5 times what I paid for it!


Paired with a 80mm flexible pipe and some zip ties the job was done,.. and it is a nice snug fit!.. You can't really see it in this photo but it is literally right up against the back of the duct on the cover.


On the other side I carefully removed the 2 circlips and centre clip to remove the plastic piece and fitted some aluminium grill mesh in its place to protect the oil cooler.


I also cut up a plastic lid from an old tool box and made a makeshift duct for the oil cooler, I will have another stab at this if it needs more cooling/better channelling after I have seen what the temps are like, needless to say its a bit temporary!


After putting it all back together again I had time left to clean off all the little bits of metal sitting all over my car!


I think its turned out fairly well! The main thing is that I have kept my promise to Wanda and not altered the external appearance so she is happy! and the stealth look is complete!.


open the hood!!



Its booked in for some fettling with FB Tuning on Thursday. The oil cooler lines and thermostatic plate (thanks Greg!), 650cc Injectors + Perrin intake pipe and a re-map!

Cant wait!.. more to follow.
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Last edited by Ginola; 17-03-2014 at 09:04 PM.
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Old 16-03-2014, 09:23 PM
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Cracking job you've done there Dave wouldn't think you've just fitted a FMIC until you open the bonnet
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Old 16-03-2014, 09:39 PM
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+1 on a cracking job Dave

I do hope you did a Ron and cleaned behind the bumper whilst it was off

Hope Wanda`s back is ok? Perhaps Liz and Wanda could start-up their own `crap back` club?
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Old 16-03-2014, 10:02 PM
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Looks very good dave nice and stealth.
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Old 16-03-2014, 10:10 PM
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That is extraordinarily stealthy.

Very nice job.
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Old 16-03-2014, 10:30 PM
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Good work Dave, how many pints of coffee were consumed in the making
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Old 16-03-2014, 10:30 PM
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Well done quality work.
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Old 16-03-2014, 11:02 PM
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That looks a cracking job mate, really can't tell until you lift the bonnet. Good work!
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Old 17-03-2014, 07:40 AM
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Great write up Dave - looking good!
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Old 17-03-2014, 08:29 AM
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Looking good but where's all the pictures of the scary bit, hacking the bumper about???
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Old 17-03-2014, 08:51 AM
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Great write up Dave looks awesome stealth mode
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Old 17-03-2014, 11:32 AM
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Cracking job that, well done
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Old 17-03-2014, 12:34 PM
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Nice one mate, looks good!
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Old 17-03-2014, 02:00 PM
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Great job
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Old 17-03-2014, 08:53 PM
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Cracking Job!!
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Old 17-03-2014, 09:12 PM
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Cheers guys for the kind comments, hopefully the results will be decent enough for the work put in, X fingers!


Quote:
Originally Posted by Bolesroor View Post
+1 on a cracking job Dave

I do hope you did a Ron and cleaned behind the bumper whilst it was off
Hope Wanda`s back is ok? Perhaps Liz and Wanda could start-up their own `crap back` club?
Hehe I brushed it out with a brush *(very quickly to get all the lose burnt plastic out!! :P but didn't clean clean shame on me, I did however start rust treating the underside while I was lying down there! Wanda has lots of problems with her back and the docs just seem to fob her off with prescription pain killers all the time which she keeps trying to give to everyone!

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Good work Dave, how many pints of coffee were consumed in the making
MANY PINTS!!! I think nearly half a kilo!!

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Originally Posted by SilverSurfer View Post
Looking good but where's all the pictures of the scary bit, hacking the bumper about???
I forgot to take any really brutal ones probably because I was too busy changing dremel blades and burning myself with molten plastic ... I bought a box lot of cheap and cheerful Dremel accessories from Halfrawds for about 8 quid, came with many cutting discs! used all of um! still a much better deal than buying proper Dremel stuff where you get 4 or 8 blades for 15 quid
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Old 17-03-2014, 09:25 PM
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Good job, I did my front bumper with a Dyney, far less stressful!
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Old 17-03-2014, 09:30 PM
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Good job, I did my front bumper with a Dyney, far less stressful!
Whats a Dyney? sounds like a tool to have.
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Old 17-03-2014, 10:14 PM
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Some have said he's a bit of a tool!
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Old 17-03-2014, 10:15 PM
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Some have said he's a bit of a tool!

Haha!
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Old 17-03-2014, 11:06 PM
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Very nice job similar to what I have done and you may not need any more ducking on the oil cooler as in the cold weather mine works a be to well.
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Old 18-03-2014, 12:17 AM
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Very nice job similar to what I have done and you may not need any more ducking on the oil cooler as in the cold weather mine works a be to well.
Cheers dude, I had looked at where you had mounted yours and how you had ducted it with the nicely made ducting, yours is far more advanced than this. A lot of air can still escape over the top of the cooler and also up through behind the headlight. Will see how well it performs on the Mapping session and go from there.
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Old 18-03-2014, 08:31 AM
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very well done
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Old 18-03-2014, 10:53 AM
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Great work there and looks very stealthy

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Looking good but where's all the pictures of the scary bit, hacking the bumper about???
Have this one of when i did my FMIC lol

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Old 19-03-2014, 03:45 PM
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Quote:
Originally Posted by Ginola View Post



Sunday dawned and only had a few jobs left to do.. Sorting the cold air feed for the intake and making sure everything was clipped and trimmed back in place where it should be.
I managed to get hold of a large rubber snorkel that just so happens to be the exact same size as the intake on the STI front fog cover!! this cant be known to anyone otherwise the price would have been 5 times what I paid for it!
Is the snorkel you used the OEM one that is originally fitted? Mine didn't have one when I bought it.
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Old 19-03-2014, 04:05 PM
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Very cool! I'd have been cacking it taking a grinder to my bumper! Thought I was brave hacking my grill to pieces
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Old 19-03-2014, 05:56 PM
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Quote:
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Great work there and looks very stealthy



Have this one of when i did my FMIC lol

and that aps one was huge!
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Old 19-03-2014, 07:01 PM
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Hats to you Dave, a cracking job and not one I would wish to tackle!!!
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Old 19-03-2014, 07:39 PM
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and that aps one was huge!
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Old 19-03-2014, 08:19 PM
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Quote:
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Is the snorkel you used the OEM one that is originally fitted? Mine didn't have one when I bought it.

No, found an aftermarket one, there is no OEM snorkel down there, as the resonator box that sits in the wing takes all its air from the top snorkel.. I might see if I can nab a few more of them, made from rubber they fit an 80mm pipe
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Old 19-03-2014, 08:20 PM
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Quote:
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Hats to you Dave, a cracking job and not one I would wish to tackle!!!

Cheers dude

Aye those APS ones and the hyperflow monster ones are exactly that...monsters!
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Old 19-03-2014, 09:49 PM
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Quote:
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No, found an aftermarket one, there is no OEM snorkel down there, as the resonator box that sits in the wing takes all its air from the top snorkel.. I might see if I can nab a few more of them, made from rubber they fit an 80mm pipe
Ah I see. Yeah I knew there wasn't one down there, mine didn't come with the original set up, just the air box which is why I put the fog inserts in with duct running to the airbox. Trouble is when it's really wet it sucks water in which my MAF doesn't like. If you can get gold of some more, I'd definitely take one off of you as that looks like a good solution to my problem
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Old 19-03-2014, 11:33 PM
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Cracking job Dave, will come to you if I ever get a front mount on mine
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Old 22-03-2014, 08:52 PM
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After getting home from the meet today I couldn't resist the niggling bit of the install I had left out completing.. The bottom pipes on the HDI FMIC kits run under the car and as such are a bit of a pain to get sitting neat and high enough off the deck! On my 05 car there are 2 studs for bolting the bottom factory cross brace to..not bolts/nuts they also sit right on the bend path for the FMIC pipe.. causing all sorts of positioning and potential puncture nightmares.

Various instructions on several forums by Harvey Smith(RIP) and other people that have fitted these kits mention turning the bolts round, however on my car there are no bolts but studs..

Taking an angle grinder to these to shorten them down to the height of the nut on them was the only solution, ...(partially deaf now!)

Before.. not good!


After pipes adjusted.. much better!


The exhaust at the back is most certainly lower.. and never gets hit.. so feeling a lot better about the overall fit of the thing now.

Engine splash tray re-fitted
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Old 22-03-2014, 09:02 PM
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Nice job, when is the remap booked?
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Old 22-03-2014, 09:08 PM
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Nice job, when is the remap booked?
Cheers, mapping booked for this Thursday, along with fitting 650cc injectors, Perrin intake pipe, parallel fuel rail mod, thermal spacers and finishing the oil lines off for the oil cooler.

Hopefully all ready for Goodwood in a couple of weeks!
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Old 25-03-2014, 04:38 PM
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What an awesome thread! Looks awesome!
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Old 31-03-2014, 10:32 PM
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How did it go on Thursday Dave, all good and happy with the results I hope.
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Old 31-03-2014, 10:53 PM
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How did it go on Thursday Dave, all good and happy with the results I hope.
Happy ye Didn't get time to dyno due to 1 or 2 unforeseen problems such as the oil cooler core leaking on a weld!!! Think automotive agreed to replace, but buying one from spectrum hoses that where only 15mins down the road was a much better option! After mapping was done I rushed home as it was Fathers birthday, and 72nd members meeting the next day! Got in at 9.30pm Father and Handbrake had already drunk 3 bottles of wine!)

The car goes very well Thermal gaskets fitted, injectors, oil cooler etc all working well, looking forward to stretching its legs on Saturday! I put 3 or 4 heat cycles through a set of 888s! so should be good fun... .if it stays dry!

I wouldn't like to guess at power, 75% injector duty at 3bar fuel pressure injectors are flowing at 700cc.. If anyone can do a rough guestimate from that feel free! It took quite a few more degrees of timing at the top with the FMIC fitted
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Old 31-03-2014, 11:42 PM
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Some makeshift ducting, ziptied bits of mudflap!



Some 888s on the track wheels.. The boss said.. "Are those road legal!!"
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Old 01-04-2014, 12:06 AM
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I bet those tyres have some grip on them Dave .
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Old 01-04-2014, 01:55 AM
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I bet those tyres have some grip on them Dave .
They do! The difference between these and a regular road tyre is night and day,.. though I have yet to drive on them in the wet..
Now to see how many track days they last! and if my baffled sump is upto the task of staving off oil starvation I took them of the car tonight as they have done about 115 road miles. I wanted to heat cycle them a couple of times to firm them up a bit in an effort to make them last!
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Old 01-04-2014, 09:06 AM
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It looks amazing, and that snorkel ideal is cracking ! wonderful tasteful mods, and great work...
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Old 01-04-2014, 09:06 AM
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Just wait til you try the triple 8's on the circuit........
They push the boundaries much farther than you'd expect
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Old 01-04-2014, 11:19 AM
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Just wait til you try the triple 8's on the circuit........
They push the boundaries much farther than you'd expect
Agreed, never driven with them myself but was shocked at how well they gripped on Neil's Evo X.
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Old 01-04-2014, 08:10 PM
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Glad the knocking noise was only something bumping on your shaft.......
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Old 01-04-2014, 08:33 PM
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Glad the knocking noise was only something bumping on your shaft.......
hahah
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Old 02-04-2014, 02:29 PM
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Old 13-04-2014, 05:24 PM
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Quick update. I thought I would leak test the FMIC prior to getting a new turbo fitted and sort out any remaining niggles with the system so as not to cause any undue problems when mapping.

So off to the local plumbing supplies shop and £1.95 for a 2" waste pipe end. (with rubber sealed cap!) I drilled a hole in it and mounted a nice super light weight aluminium tyre valve in it!.. (hey our pressure test kit needs to be light weight!! :P)



I used a tyre pump to apply pressure to the system once I had capped the other end off with an old paint can, some tape and a couple of jubilee clips. I then sprayed over the pipe joins with a fairy liquid and water solution.
Much to my annoyance there where tiny leaks at nearly every pipe junction! Indicated by big bubbles forming all over the place, despite the hose claps being tight enough to bend the bolts holding the claps!! I have since replaced the hole lot with Jubilee clips (took 3 hours to do this without removing the Bumper! and hey presto more pressure and no more leaks!!) Annoyed at HDI a little I am!
clamps anyone?

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Old 13-04-2014, 07:26 PM
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Hongkongfooi Hongkongfooi is offline
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good effort. you wouldn't have had time for ps3 today then
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