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#1
16-03-2014, 08:45 PM
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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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Somewhere drinking Coffee Mapped and maintained by FBTuning 07595 493581. Last edited by Ginola; 17-03-2014 at 09:04 PM. 
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#5
16-03-2014, 10:10 PM
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That is extraordinarily stealthy.
Very nice job.
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#6
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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#9
17-03-2014, 07:40 AM
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Great write up Dave - looking good!
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#12
17-03-2014, 11:32 AM
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Cracking job that, well done
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#16
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:
 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!Quote:
  Quote:
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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Somewhere drinking Coffee Mapped and maintained by FBTuning 07595 493581.
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#17
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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2005 Spec B 6MT - KiDO tuned (~270Bhp)
Custom exhaust - Cosworth filter - Samco Intake - Tints - Bilstein B8/B6 & STI springs - SuperPro ALK - Whiteline positive shift kit, rack mounts, rear adjustable camber bushes, front ARB mounts & strut brace, 20mm rear ARB with AVO mounts, - Hardrace Gearbox and pitch mounts - Prodrive PFF7's - Front Brembos - Kenwood CarPlay - 1/2 carbon grille - STI front splitter
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#18
17-03-2014, 09:30 PM
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Quote:
 sounds like a tool to have.
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Somewhere drinking Coffee Mapped and maintained by FBTuning 07595 493581.
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#19
17-03-2014, 10:14 PM
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Some have said he's a bit of a tool!
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2005 Spec B 6MT - KiDO tuned (~270Bhp)
Custom exhaust - Cosworth filter - Samco Intake - Tints - Bilstein B8/B6 & STI springs - SuperPro ALK - Whiteline positive shift kit, rack mounts, rear adjustable camber bushes, front ARB mounts & strut brace, 20mm rear ARB with AVO mounts, - Hardrace Gearbox and pitch mounts - Prodrive PFF7's - Front Brembos - Kenwood CarPlay - 1/2 carbon grille - STI front splitter
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#21
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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#22
18-03-2014, 12:17 AM
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Quote:
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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Somewhere drinking Coffee Mapped and maintained by FBTuning 07595 493581.
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#24
18-03-2014, 10:53 AM
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Great work there and looks very stealthy
 Quote:
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Not built for the Twisty's
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#25
19-03-2014, 03:45 PM
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Quote:
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Smiles Per Gallon >>>>>>>> Miles Per Gallon
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#27
19-03-2014, 05:56 PM
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Quote:
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#28
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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10 Years of Scoobies:04 WRX SL, 06 HAWK STI, 97 JDM WRX STI WAGON, 05 WRX STI, MK3 FOCUS RS, now Porsche Cayman S
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#30
19-03-2014, 08:19 PM
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Quote:
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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Somewhere drinking Coffee Mapped and maintained by FBTuning 07595 493581. Last edited by Ginola; 19-03-2014 at 08:40 PM.
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#31
19-03-2014, 08:20 PM
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Quote:
Cheers dude Aye those APS ones and the hyperflow monster ones are exactly that...monsters!
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Somewhere drinking Coffee Mapped and maintained by FBTuning 07595 493581.
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#32
19-03-2014, 09:49 PM
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Quote:
__________________
Smiles Per Gallon >>>>>>>> Miles Per Gallon
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#34
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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Somewhere drinking Coffee Mapped and maintained by FBTuning 07595 493581. Last edited by Ginola; 22-03-2014 at 08:55 PM.
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#36
22-03-2014, 09:08 PM
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Quote:
Hopefully all ready for Goodwood in a couple of weeks!  
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Somewhere drinking Coffee Mapped and maintained by FBTuning 07595 493581.
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#39
31-03-2014, 10:53 PM
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Quote:
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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Somewhere drinking Coffee Mapped and maintained by FBTuning 07595 493581. Last edited by Ginola; 31-03-2014 at 10:55 PM.
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#40
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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Somewhere drinking Coffee Mapped and maintained by FBTuning 07595 493581.
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#42
01-04-2014, 01:55 AM
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Quote:
 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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Somewhere drinking Coffee Mapped and maintained by FBTuning 07595 493581. Last edited by Ginola; 04-05-2014 at 08:34 PM.
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#44
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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#45
01-04-2014, 11:19 AM
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Quote:
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#46
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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#47
01-04-2014, 08:33 PM
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Quote:
 
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Somewhere drinking Coffee Mapped and maintained by FBTuning 07595 493581.
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#49
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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Somewhere drinking Coffee Mapped and maintained by FBTuning 07595 493581.
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#50
13-04-2014, 07:26 PM
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good effort. you wouldn't have had time for ps3 today then
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