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K9F



Member Since: 12 Nov 2009
Location: Bournemouth
Posts: 9610
United Kingdom 2008 Defender 90 Puma 2.4 XS CSW Stornoway Grey
Nice work! Pity the poor soul that doesn't have your ingenuity, materials or tooling to make the veritable silk purse out of a sow's ear. Very well done!

Thumbs Up If you go through life with your head in the sand....all people will see is an ar5e!!

Treat every day as if it is your last....one day you will be right!!
Post #264667 8th Sep 2013 8:40pm
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Skye_Rover



Member Since: 30 Aug 2013
Location: Skye
Posts: 85
Scotland 1998 Defender 110 300 Tdi CSW Cairns Blue
Yes, excellent job. Far better to get the installation done once, and done right. You are correct to be concerned about the intercooler outlet pipe to to the inlet manifold. Any chance you can get some movement outboard towards the inner wing to clear the water pump? The standard pipework seems to take a slight detour in that direction. Or perhaps cut the I/C outlet stub shorter and use some of the original pipework? The problem of some of these aftermarket pipes is that they are fabricated with welds for bends, whereas a less "fancy" option would have been to use a proper formed steel tube (similar to original); less trendy, but a better engineering option for clearances and airflow. Roads? Where we're going, we don't need roads.
Post #264690 8th Sep 2013 9:25pm
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taazzukcb



Member Since: 30 Aug 2013
Location: Derbyshire
Posts: 663
United Kingdom 2004 Defender 110 Td5 DCPU Stornoway Grey
I've wiggled, jiggled and waggled everything I could (then had a go at the pipe, ha!) and managed to get around 3-4 mm clearance. Still not enough in my eyes!

I'll give it a few heat cycles, see if I can get the fresh silicone to loosen up a little then have another wiggle.

I don't understand why they didn't use proper mandrel bends. Far better, far more accurate and a much much higher % of getting each bit the same. Thing with welding (even robotic, but much tighter tolerances there) is that there's so many potentials of changes and errors, thus making everything not quite the same, so one could be bob on whilst the next a little out! Even on a decent jig!

I've considered using the original rubber pipe work yes, just a shame to loose the shiny shiny and blue rubber :p! Perhaps a pure silicone hose would be a better option? As in, without the metal!
Post #264704 8th Sep 2013 10:03pm
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