Project "Monty"

[Dale]

Awesome exhaust where is this badger 5 ???

Stonehouse, Gloucestershire! Does all my dyno work/engine setup on monty

[corsakid]

Cool never heard of him before?... Might ask him to do exhaust on merc

[Dale]

Cool never heard of him before?... Might ask him to do exhaust on merc

Mainly does Vag.... Met him couple years ago through that Ibiza I do work on... Have a look through this link Badger5 - SEAT Cupra.net - SEAT Forum Races at Combe and has some big powered builds and doesn't talk **** my sort of bloke!!!

[Col004]

Looks great Dale.. what management you going to be running mate?

[corsadonk]

Looks very meaty.

[Dale]

Looks great Dale.. what management you going to be running mate?

Cheers, will be on Motec

Looks very meaty.

Cheers lover... car looks good too

[corsakid]

Why motec mate??? Surely dta, omex etc will be more than enough , not to mentioned cheaper

[rc]

very tastey

[Dale]

Why motec mate??? Surely dta, omex etc will be more than enough , not to mentioned cheaper

Long story and compairing them I would rather use it more feature etc and my friends (Lives to 2mins from my house) distributes them and makes the wiring looms for Owen Developments who will also be mapping the car!!! Price doesn't fuss me car isn't going anywhere.... I'm not the sort to sell, I just buy more!!

very tastey

Cheers

[Kev_G]

ive jizzed my pants

[Ardenblueroy]

ive jizzed my pants

Make that 2 of us....work of art.

[Dale]

ive jizzed my pants

Make that 2 of us....work of art.

Cheers

[Dale]

Little Update:

Got a few bits through and managed to get some time in the garage tonight.

New twin 8" fans



Mounted on radiator, will be on the front now as now room at the back!



Radiator in place with fans



Then I started "mocking" the intercooler setup....

Passenger side from cooler to Inlet




Turbo to intercooler





Then I made a pikey intercooler mock



Rough sizes and where I'm upto so far



Cheers

[jonlem]

Looking good Dale. Have you fitted a filter in the turbo oil feed line ?

[Dale]

Looking good Dale. Have you fitted a filter in the turbo oil feed line ?

Cheers, I measure that gap over weekend for you! Yer the feed has a filter. Still got loads to do tho

[Rallycorsa]

Might be worth changing the way you have the fans mounted by using cable ties, cut one end off and use them straight through instead of the bolts ,the bolts will vibrate against the soft ally rad and might cause failure.

[vxlaney]

[QUOTE=Rallycorsa;4589328]Might be worth changing the way you have the fans mounted by using cable ties, cut one end off and use them straight through instead of the bolts ,the bolts will vibrate against the soft ally rad and might cause failure.[/QUOTE
or even these from ebay,

eBay - The UK's Online Marketplace

[Benn]

Looking good dude, piped up easily from the looks of things. I use the plastic push thru lug things to hold the fans on, and two cable ties where its right by the turbo.

[Rallycorsa]

no need for the straight type ones on ebay, and the cheap ones snap as i found out, just cut the end off an ordinary cable tie and hey presto ;-)

[Corsamitch]

Might be worth changing the way you have the fans mounted by using cable ties, cut one end off and use them straight through instead of the bolts ,the bolts will vibrate against the soft ally rad and might cause failure.

Agreed, I'd use either cable ties or get the proper rad fasteners, I got mine from burton power but loadsa places do em...

[Dale]

Cheers for comments guys, I just used the fasteners that came in the kit, they have preload to stop fans moving about and rubber washers to stop damaging of rad! I have plastic fan ties as I used these on my last fan setup! I still have loads spare so I'll just change to them!!

[Dale]

Been working away on the intercooler design over the weekend and I'm now on plan "B" So this is the current design....

[Dale]

Well been really lazy recently.... But hey ho onwards and upwards!

Intercooler has been ordered and is on design "C" now lol, should be here next week.

So time to crack on with the rest then! First off was to move Vinnie to my spare garage and get monty is the "gready" position!





Then it was time to get him up in the air to route new fuel setup.




Location of new areoquip FPR (excuse the tape )



List of parts for fuel system I need so far...



Currently half way through the mock fitment of the fuel system. Currently the setup below only shows return from rail to swirl pot and swirl pot to tank.



Through body connections



I will update with better pictures once all the fittings have been delivered.

[Dale]

Had some free time this weekend so got cracking with monty...

First off was to carry on sorting the fuel system out.

Making the -8 hose from the swirl pot to bosche 044 pump..



Getting there now



New fuel goodies turn up



Free flow 90deg to replace "forge" 90deg (better flow)




Twin fuel filter bracket



Through body free flow vs old "forge" item



Getting there...





I Still have to make/attach lines from tank to "low flow" fuel filter and swirl pot to tank return.

As it stands the fuel system goes...

All hoses in PTFE braided lines with -6 fittings bar swirl pot feed to 044 pump which is -8

Standard Fuel tank
Walbro 255l Pump used as a Lift pump to fill swirl pot
Sytec low flow filter
2 litre swirl pot
Bosche 044 fuel pump
Sytec High flow filter
Aeroquip FPR
Injector dynamic 1000cc injectors

Then this parcel came



Inside



quick check to see if my cardboard mock worked.... The design has changed since design pictures. It uses a 70mm core as per design but now uses 80mm end tanks rather than 72mm the design had...



Worked well for me

I mounted the radiator and made brackets rather than good old cable ties but no pictures! Cut the slam panel out as i want it removable.

Mocked the intercooler fitment and welded the lower brackets. I'm yet to make the top hence the cable tie




Check fitment with bonnet shut (ignore the dirt he is very dirty )





And I removed the seats and all my old guage wiring inc wideband as this will all be replaced



Not bad for a Sundays work...

[Th0m45]

Good work mate! How are you going to have the front bumper with that monster fmic?