Custom FMIC - design considerations

[Robbie C]

Quick update - got my cooler from Forge yesterday and it looks top notch

Looks like my measurements worked out well as it appears very similar to the AM cooler I wanted to replicate, as per David Smith's/Chris Curzon's/Cupra Neil's old setup.

My only concern as such is that the core itself is only 60mm deep whereas I requested 65mm, but they've taken that measurement as the end tank depth so it steps down 5mm to the core. In real world terms I can't see it making a difference, just means the volume is less than anticipated, now 5508000 mm^3. The internals themselves look very well built.

I'll be getting this aligned on the car ready to take up to RS Fabs in the next 3-4 weeks so watch this space.

 

[DaNnY_LaD]

Quick update - got my cooler from Forge yesterday and it looks top notch

Looks like my measurements worked out well as it appears very similar to the AM cooler I wanted to replicate, as per David Smith's/Chris Curzon's/Cupra Neil's old setup.

My only concern as such is that the core itself is only 60mm deep whereas I requested 65mm, but they've taken that measurement as the end tank depth so it steps down 5mm to the core. In real world terms I can't see it making a difference, just means the volume is less than anticipated, now 5508000 mm^3. The internals themselves look very well built.

I'll be getting this aligned on the car ready to take up to RS Fabs in the next 3-4 weeks so watch this space.

How much was that!!!

It does look good tho...

 

[ChrisCurzon]

I wanted to replicate, as per David Smith's/Chris Curzon's/Cupra Neil's old setup

That cooler got around, must be the site slag

Does look very similar mate, i no you said on your texts that you were concerned on the measurements but they sounded right too me, and that looks pretty much the same to me

Getting there mate, happy days! Charge pipe next

 

[Robbie C]

Yes mate I think it's near as damnit so all good Cheers for your help with those

Yeah just waiting on Alex at BDM for some rad brackets to move that back and then I'll get it bolted on the car and lined up ready for the pipe work. Once that's done it's all set for the hybrid

 

[Myki da Pyki]

Looks good rob, the usual top quality by forge. Did they say why they didnt make it to the dimentions you requested?

 

[Robbie C]

Cheers Myki. I gave them the drawing on page 3 to work from and it looks as though it was interpreted slightly incorrectly, but in all honesty I don't see it being an issue.

The end tanks are 65mm and the core itself is 60mm whereas I wanted the end tanks to sit flush with the core, 65mm all the way down - it maybe that this isn't possible. Either way, I'm still pretty happy with it.

 

[Myki da Pyki]

Yeh think the end caps are always slightly bigger, was the same on mine.

Will look sweet once its all done mate, much better than the ready made forge kit and the usual ebay kits of late

 

[Robbie C]

here's hoping. Admitedly it's more hassle the way I'm doing it but should offer one of the most efficient and free-flowing setups to perform well with my hybrid.

 

[Myki da Pyki]

Thats the whole idea of a front mount at the end of the day rob. Glad to see it coming along now aswel mate

 

[Robbie C]

Right, the saga continues....

After speaking to CupraGaz who still owns an AM FMIC he double checked these measurements and found the core height to be incorrect at 170mm, where it should be 195mm - making the core some 20% smaller than intended.

After having a serious think I decided to sell this FMIC and ended up re-ordering with Pro Alloy this afternoon, using a new updated design with a core of 560 x 195 x 63 (Pro Alloy can't supply 65mm cores so I've made it 20mm longer than the standard AM core to compensate for the lost volume)

Some people may find the following (amended) core dimension tables below quite useful (all measuremnts given in mm):

AM Motorsport FMIC:
=======================

Core size:  540 x 195 x 65 = 6844500


Forge Ibiza MK3 FMIC:
===================

Core size: 450 x 350 x 40 = 6300000


Myki's Custom Forge FMIC:
======================

Core size: 730 x 220 x 40 = 6424000


THS Universal FMIC:
=================

Core size: 530 x 157 x 65 = 5408650


Ebay Universal FMIC:
==================

Core size: 530 x 140 x 65 = 4823000


Rob's Forge FMIC:
================

Core size: 540 x 170 x 60 = 5508000


Rob's Pro Alloy FMIC:
==================

Core Size: 560 x 195 x 63 = 6879600


Pro Alloy FMICs:
===============

Core size 1: 580 x 310 x 40 = 7192000 (this keeps air con)

Core size 2: 540 x 310 x 50 = 8370000 (this one requires the removal of air con)

The Pro Alloy and Forge dimensions have been verified by the suppliers themselves so this might come in handy for a few of you.

As you can see I've gone for a core size that's somewhere in-between the standard Forge and Pro Alloy sizes, but I'm using a shorter wider design that will utilise more of the air coming through the mesh of the bumper for maximum cooling (this is offset against pressure drop in extreme circumstances)

I've decided to adopt Danny Lad's approach to the pipework and order a universal 2.5" pipe kit from ebay, using my own silicone hoses and clamps. I want to join it slightly differently to Danny so I'll post a guide up when it's done in case anyone else wants to follow this example in the future. This also means I can do all of the hybrid work on the car at the same time and save the hassle of having to send the car off for a week to get the bends welded.

Expected turnaround from Pro Alloy for the FMIC is 2-3 weeks so I'll post pics up when it arrives and is ready to be fitted

 

[cuprachrissy]

i just done the tt/lcr pipework route in 2.5", would post pics up but my car is at the bodyshop having a lick of paint! dint do itr like reuvers n danny lads in the end just came straight down, not under the washer bottle etc.
those core sizes look interestin too mate, i have ebay jobbie and cant fault it tbh, perfect for my k03s

 

[Robbie C]

I think for a standard K03S build it's not so much of a worry. If you've routed the charge pipe straight down the front does it make a sharp bend to enter the intercooler? I think this may be why others go down the side of the wing, to allow smoother air flow.

 

[cuprachrissy]

I think for a standard K03S build it's not so much of a worry. If you've routed the charge pipe straight down the front does it make a sharp bend to enter the intercooler? I think this may be why others go down the side of the wing, to allow smoother air flow.

no sharp bends mate, all good where i was looking! ill get some pics up when my car is out of the sprayers.

 

[Robbie C]

Sounds good, would be interested to see exactly what route you've used

 

[danielc16]

fimc

i have fitted my front mount just need to pipe it up but i did not need to cut alot of the bupmer due to me moveing the rad back

here i move my rad back:

then made the pipe work route:

got my dad to weld me some brakets:

once we knew it was right he welded it up as it was spot welded to see if it works then i painted it:

now fitted:

now i got the pipe work to do and trim the bumper ends but i can fit the bumper without cutting it,

 

[danielc16]

just orded the pipe work in steel so ican start it

 

[Robbie C]

Nice one - that an ebay cooler?

 

[danielc16]

Nice one - that an ebay cooler?

na its bigger the core is: 550 x 180 x 65 and the whole ic is 700 x 180 x 65
just added the the core to give me the total and its 6435000

 

[Robbie C]

Sounds good, similar dimensions to my custom Pro Alloy core. Where did you get that one from?

 

[danielc16]

Sounds good, similar dimensions to my custom Pro Alloy core. Where did you get that one from?

it came from germany but it was soon quick on delv got it in 3 days just brought all my pipe work as well and will keep you up dated