Barn's Project....returning to a leon.

[cupra-barn]

After a very long day, my arm feels like its about to drop off but I got it finished. 10 hours spent in total just giving it that extra bit of TLC it needed.
Dodo'd the whole car by hand and amazed with the results.

And the final reflection.

 

[cupra-barn]

FMIC is fitted!

First things first, thank you Phill. 11 hours spent on it and I really appreciate the help. Tim thanks for doing the logging and supplying comedy value to the day.

I got to Phills at half 8 and the planks of wood were already laid out to drive straight on and jack do we could get a jack under it (forward planning by phill)

We started by removing the TIP, slackening all the existing pipe work and splitting the loom to allow the TB and Map sensor to plug in. Really easy as all the wiring is doubled over on the fuel rail do just unfolds to the correct length.

Next we removed the inlet manifold and pushed the fuel rail aside so I could clean the face for the new gasket.

Followed by refitting the new inlet manifold and fuel rail. It's a slightly modified LC fuel rail so's not to foul on the fuel rail. (no pic)

Got the car up in the air and removed the wheels and wheel arch liners to allow access to fit piping and to remove old piping.

It was the bumper and slam panel off to mock up the intercooler and make some brackets.

Picture break

 

[cupra-barn]

Unfortunately the brackets I had made didn't line up do they were removed and we made some new ones.

Bottom bracket-

With the cooler hung phill drilled out the rivets on the slam panel. This allows the large back square to come off letting this large cooler sit behind it without needing to actually cut the metal.

The angle grinder then reappeared to trim the fog light surrounds and scoops off to allow for the piping.

As you can see from the pictures you need to trim a fair bit off but you can still retain the brackets to bolt the bumper on.

We then turned to routing the pipe work starting at the turbo-charge pipe. Straight away we hit a problem. The forge to hose I had was far too long, a good couple of inches so off phill disappeared into his little cave of car parts to make me something, and he did!

My very own top hose (it now has a joiner holding it on the turbo)

Once that was sorted it was just a case of fit the pipe work with a lot of measuring and cutting and remeasuring etc

With that done and a mock figment of the bumper carried out we roughed the edges of the pipes and bent a lip on them and done everything up tight.

 

[cupra-barn]

The final result is ace, looks great and definitely does the job!

I now have my LCR charge pipe, inlet mani and fuel rail fitted.

The cooler itself sits perfect, fills the whole grill and looks the part. Really happy with the cosmetic side.

So after going home and spending a bit of time with the misses, I headed over to Tims (Ronin225) for a short logging session.

Grams per second hasn't increased at all. I still can't brake the 179. Today saw 179.58gs. However the huge difference is the intake temps (obviously lol)
With an ambient temp of 9degrees my I take temps were ranging from 18-14 cooling more the faster I went. The torque has definitely improved, and seems to have a smoother delivery of power.

All in all, a great day with some awesome guys, a wealth of knowledge, money well spent and a large smile

Once again, cheers for the help guys!

 

[sambryant]

Nice install. I fitted a welly cooler this week for a mate of mine, we managed to fit the fogs too which is a bonus. Enjoy the extra torque and lower intake temps. There maybe room to add a little more timing

 

[RDS]

Nice work mate, I've still got mine itting around waiting to go on.

 

[cupra-barn]

Nice install. I fitted a welly cooler this week for a mate of mine, we managed to fit the fogs too which is a bonus. Enjoy the extra torque and lower intake temps. There maybe room to add a little more timing

Yeah I've still got the brackets to mount the fogs, but I've never actually had them lol

 

[Ronin225]

Heres the logs from last night, ran 3 blocks at the same time tob be able to see all the figures we wanted to

06A 906 032 DE		1.8L R4/5VT         0001													
															
	Group A:	'004				Group B:	'003				Group C:	'020			
		Engine Speed	Voltage Supply	Coolant	Intake Air		Engine Speed	Intake Air Mass	Throttle Drive	Ignition		Cylinder 1 Ignition	Cylinder 2 Ignition	Cylinder 3 Ignition	Cylinder 4 Ignition
	TIME			Temperature	Temperature	TIME			Angle Sensor 1	Timing Angle	TIME	Angle Delay	Angle Delay	Angle Delay	Angle Delay
Marker	STAMP	 /min	 V	°C	°C	STAMP	 /min	 g/s	%	 °BTDC	STAMP	 CF	 CF	 CF	 CF
	0.83	2800	13.72	76	20	0.01	2560	58.83	79.6	21	0.43	0	0	0	0
	2.05	3240	13.65	76	17	1.23	2920	103.97	100	11.3	1.63	0	1.5	0	1.5
	3.34	3760	13.72	76	15	2.54	3440	124.89	100	12.8	2.94	1.5	1.5	0	1.5
	4.66	4240	13.72	76	15	3.74	3920	136.5	100	14.3	4.16	0.8	0.8	1.5	0.8
	5.86	4680	13.58	76	16	5.06	4400	148.5	100	15.8	5.46	0	0	0.8	0
	7.07	5080	13.79	77	17	6.27	4800	156.31	100	16.5	6.67	0	0	0	0
	8.48	5480	13.72	77	18	7.57	5200	164.69	100	17.3	7.98	0	0	0	0
	9.7	5800	13.65	76	18	8.88	5600	173.5	100	17.3	9.28	0	0	0	0
	10.99	6080	13.72	76	19	10.1	5880	177.89	100	17.3	10.59	0	0	0	0
	12.21	6280	13.72	76	18	11.39	6160	167.03	99.2	17.3	11.79	0	0	0	0

	Group A:	'004				Group B:	'003				Group C:	'020			
		Engine Speed	Voltage Supply	Coolant	Intake Air		Engine Speed	Intake Air Mass	Throttle Drive	Ignition		Cylinder 1 Ignition	Cylinder 2 Ignition	Cylinder 3 Ignition	Cylinder 4 Ignition
	TIME			Temperature	Temperature	TIME			Angle Sensor 1	Timing Angle	TIME	Angle Delay	Angle Delay	Angle Delay	Angle Delay
Marker	STAMP	 /min	 V	°C	°C	STAMP	 /min	 g/s	%	 °BTDC	STAMP	 CF	 CF	 CF	 CF
	0.01	2640	13.86	77	18	0.4	2680	70.83	93.7	21	0.83	0	0	0	0
	1.31	2960	13.79	77	18	1.71	3080	112.75	100	12	2.11	1.5	0	1.5	0
	2.51	3440	13.72	77	15	3.02	3640	121.58	100	12	3.42	1.5	0	3	1.5
	3.82	3920	13.72	77	14	4.31	4120	145.67	100	15	4.73	2.3	0	2.3	0.8
	5.23	4440	13.72	77	15	5.63	4560	151.53	100	15	6.03	1.5	0	1.5	0
	6.43	4840	13.79	77	15	6.84	5000	162.28	100	17.3	7.24	0.8	0	0.8	0
	7.64	5240	13.86	77	16	8.04	5360	169.42	100	17.3	8.44	0	1.5	0	0
	8.96	5600	13.72	77	17	9.36	5720	175.42	100	16.5	9.76	0	0.8	0	0
	10.17	5920	13.72	77	18	10.67	6040	179.58	98.8	15.8	11.07	0	0	0	0

	Group A:	'004				Group B:	'003				Group C:	'020			
		Engine Speed	Voltage Supply	Coolant	Intake Air		Engine Speed	Intake Air Mass	Throttle Drive	Ignition		Cylinder 1 Ignition	Cylinder 2 Ignition	Cylinder 3 Ignition	Cylinder 4 Ignition
	TIME			Temperature	Temperature	TIME			Angle Sensor 1	Timing Angle	TIME	Angle Delay	Angle Delay	Angle Delay	Angle Delay
Marker	STAMP	 /min	 V	°C	°C	STAMP	 /min	 g/s	%	 °BTDC	STAMP	 CF	 CF	 CF	 CF
	0.8	2840	13.86	77	17	0	2640	65.56	87.1	21.8	0.4	0	0	0	0
	2.01	3320	13.79	77	15	1.2	3000	107.11	100	12	1.6	1.5	1.5	0	1.5
	3.42	3840	13.86	77	14	2.51	3520	129.75	99.6	12	2.91	0.8	1.5	1.5	0.8
	4.62	4320	13.79	77	15	3.82	4000	141.17	100	15	4.22	0	0.8	0.8	0
	5.82	4760	13.86	77	15	5.02	4480	152.17	100	15.8	5.42	0	0	0	0
	7.13	5160	13.72	77	15	6.24	4880	161.53	100	16.5	6.74	0	0	0	0
	8.46	5560	13.79	77	17	7.53	5280	171.14	100	17.3	7.95	0	0	0	1.5
	9.85	5920	13.86	77	18	8.94	5680	174.53	100	17.3	9.36	0	0	0	0
	11.07	6200	13.65	76	18	10.27	6000	178.44	100	17.3	10.67	0	0	0	0

 

[Phillc]

I think it would be interesting to run comparison runs using my old jetex against the piper cross, the jetex may flow a bit more?? or get one of the green filters Tim and i have. Also mate i would get a 70mm reducer from the turbo to "New" pipe but i cant remember what the diameter is from the turbo.

 

[kevinking2020]

nice work mate, intercooler looks good.

 

[Phillc]

Just looking at the pic's again Barn, you deff need to lose the MASSIVE number plate and join the wide mouth club.

 

[Ronin225]

Just looking at the pic's again Barn, you deff need to lose the MASSIVE number plate and join the wide mouth club.

 

[Phillc]

And you.

 

[cupra-barn]

Just looking at the pic's again Barn, you deff need to lose the MASSIVE number plate and join the wide mouth club.

Not until there is a way of getting it to look exactly like the other grills. I've also noticed today the bumper is definitely not sitting right. The number plate is pointing up and you can see the black bit through the little slot above the number plate.

Hipocrit!

And you.

Glad you noticed too lol

Edit: forgot to add, 330 miles done today with no problems oh except the fuel bill

 

[Ronin225]

The black bit is the crash bar you can see and i think you'll find i was planning going widemouth anyway.
Barn i have also found the honey combe grill made from ali powdercoated black

 

[t0m]

Good work guys, FMIC looks great and is doing its job well

Small number plate time

 

[Phillc]

Not until there is a way of getting it to look exactly like the other grills.

Mine looks the same as the rest of the grills.

 

[mc funbot]

the bay is looking nice! top work

 

[cupra-barn]

the bay is looking nice! top work

Cheers mate it's getting there now

Had a boost hose come off yesterday, was surprised to find it was the hose directly off the intercooler. It's the only pipe with proper beading on so putting it down to a **** clamp that needs replacing.

I also took the front badge off and removed the carbon wrap as it was starting to peel so I've now got a nice shiny chrome surround on the front.

 

[Phillc]

I recon that was the clamp that Tim did up.