Astra Update - Intercooler fitment

Stefan · Post by **Stefan** » Sun Jul 18, 2004 9:09 pm

I've started to fit up my intercooler and rad this weekend. Wasn't as easy as I hoped it would be though due to me using the stock Astra bumper. First I tie wrapped the intercooler in position and offered up the bumper. As expected it fouled on the inside of the bumper on the plastic box section on the rear. After removing some of it with the jigsaw I offered it up again. Once again it fouled, this time on the bottom of the bumper. I couldn't cut this out as it would remove the bottom of the bumper and leave the intercooler hanging out in the breeze. I remembered that others have not had this problem with their Astra's but they normally have the GSi bumper fitted. I guess the GSi bumper has a bit more room behind it and it doesn't seem to slope in towards the car as much as the stock Astra bumper. I want to keep the cars stock-ish exterior so the only alternative was to move the intercooler intowards the rad. So out came the jigsaw again..........

Moving towards the rad means cutting the front panel so I made some marks where I needed to cut...

Then I hacked away. I left the top flange as it is where the headlight loom attaches. No going back now...

I then made up some end caps for the remainder of the front panel. Note the flange on one side to stiffen the end cap...

And welded in place...

I then welded in a length of 20x20x2SHS to support the top flange and also the slam panel. This took a while as the top flange had to be tacked in a few places, left to cool and then tacked again to minimise distortion in the thin flange. It took an hour or so to completely weld this, but it ment that it needed very little dressing with the hammer and dolly to straighten the free edge...

I've just got to make up a few brackets to hold the intercooler in position so once they're done I'll post the final pics with the intercooler in place.

Stef

2 liter turbo · Post by **2 liter turbo** » Mon Jul 19, 2004 2:07 am

Very nice! You can fit a big 'ole intercooler in there now huh?

Tony

Post by **Efratech** » Mon Jul 19, 2004 2:15 pm

Very nice Stef!

Stefan · Post by **Stefan** » Tue Jul 20, 2004 11:01 pm

More pics!

I did a few sketches of how I was going to mount the intercooler and designed some brackets that would use the stock locating pegs on the intercooler. These are the top bracket blanks I've drawn up on some 2mm thick aluminum sheet.

These are the blanks after being cut out with a jigsaw and filed up.

Finished top and bottom brackets together with grommets installed.

One of the bottom brackets welded in place and grommet fitted.

Intercooler fitted up - pic showing both brackets on one end. It's very solidly mounted.

Pic of the full width of the intercooler. There is an equal gap top and bottom and side to side. Looks almost like a professional job

It also fits behind the stock bumper.......Hurrah!!

I'll be fitting up the radiator tomorrow evening and I'll post more pics then.

Stef

AcingTeam · Post by **AcingTeam** » Wed Jul 21, 2004 2:25 am

Stefan wrote:Looks almost like a professional job

Because it is

, great job man, looks awesome, keep it up.

What kind of car is it?? Front bumper looks like a Lanos.

Tim04 · Post by **Tim04** » Wed Jul 21, 2004 2:38 am

What kind of car is it?

Wasn't as easy as I hoped it would be though due to me using the stock Astra bumper

Stefan · Post by **Stefan** » Thu Jul 22, 2004 12:00 am

More pics......

Couple of pics showing the rad in its new central location (they're normally over to the left hand side).

As you can see clearances were a bit tight. To check everything properly I had a friend come over with some silicon hoses and I fitted those up.

As you can see they just about fit! I've got to weld on some bottom brackets for the rad. I'm going to re-use the stock top brackets but I need to make some new mounting points for them.
The reason I haven't done this tonight is because I've been playing with my new turbo. After a bit more research I felt that the GT17 I was going to use would be too small. This new one is from a Ford Escort Cosworth and should easily support 200-250hp without too much lag.

Stef

Wolf-Spirit · Post by **Wolf-Spirit** » Thu Jul 22, 2004 10:18 am

nice looking tbh

keep up the good work.

KnightWalace · Post by **KnightWalace** » Thu Jul 29, 2004 1:35 pm

I wish i had 1/10 your knowledge.... i'd just work in a mechanics shop and custom do all my lanos equipment.
That Astra is going to be ... P-I-M-P.... Let us see the finish product.

daewooluvr · Post by **daewooluvr** » Thu Jul 29, 2004 2:02 pm

I agree. I like the extra 'radiator' in the front, or is that an oil cooler. haha

Sleeperish

KnightWalace · Post by **KnightWalace** » Sat Jul 31, 2004 2:04 am

How Many HP's is that Pushing?

AcingTeam · Post by **AcingTeam** » Sat Jul 31, 2004 8:13 pm

As of now... I would think.... 0.

Stefan · Post by **Stefan** » Sat Jul 31, 2004 8:26 pm

AcingTeam wrote:As of now... I would think.... 0.

yup....

Though I'm hoping for 200-250hp once built, run in and fully mapped. Doesn't sound much but its a conservative estimate

Stef

daewooluvr · Post by **daewooluvr** » Sun Aug 01, 2004 2:43 am

Stefan wrote:
AcingTeam wrote:As of now... I would think.... 0.
yup....

Though I'm hoping for 200-250hp once built, run in and fully mapped. Doesn't sound much but its a conservative estimate

Stef

Sounds great to me. 250whp is my goal

KnightWalace · Post by **KnightWalace** » Mon Aug 02, 2004 8:45 am

Shaun... i'm going to get 400... somehow... just... because i wanna beat you. I know 300 will... but... 400 is a nicer round number