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Old 08-07-2010, 12:23 PM   #1
sporadic
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Opened up the bumper for the FMIC

I'm going to lose some "sleeper" points, but I wanted to make sure the intercooler was getting enough air because I was seeing some high intake temps at the track.
I nearly put this in the non-performance section, but I can't make myself post anywhere non-technical.
I removed about 1-1/2" of material from the bumper, a couple vertical posts, and painted it satin black to blend in with the intercooler etc.
While everything was apart I also added some ducting to direct air from the passenger side part of the bumper to the air filter.
The same driver side area is just blocked off.
Not intake air temp data yet. Not sure when I'll get back to the track.


Before:





After:








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Old 08-07-2010, 02:26 PM   #2
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I really like the look of the blacked out bumpers, did you use gloss, matte, clear? Good job on having that trim along the cuts, looks really clean

Get some temp data on your mod to see if the taped up areas affect intake temperatures. A better design would have been to funnel the air toward the IC instead of blocking off those areas. How good are you with fiberglass?
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Old 08-07-2010, 02:32 PM   #3
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still looks damn "sleeper" to me..... especially to someone who doesn't own a focus. to me that FMIC looks like a condenser unit too, making it even better

glad to see a blacked out one like that though.....I wanted to do it when I went different engine and boost but wasn't sure if I could. did you paint the intercooler or did it just come like that? looks awesome.
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Old 08-07-2010, 05:20 PM   #4
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What you did will help a little , what people dont understand is the IC is like a brick wall so when the air hits it with nothing on the sides , top or bottom the air takes the path of lease resistance which is not through the IC but around it

Take some thin Alum and box the front of the cooler out as far as you can all the way to the bumper , turn the tab you install at the bottom down slightly to get more air from under as more air passes under then through , MAKE the air go through the cooler is allways the best flow and the cooles

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Old 08-07-2010, 11:04 PM   #5
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Tom I have thought about doing that a lot for the exact reasons you give. Do you recommend welding to the IC or what?
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Old 08-08-2010, 12:50 AM   #6
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Tom, I agree 100% about the air flowing around it.
My original design includes ducting around it, but this is as far as I've gotten for now.
As for fiberglass, I considered that as well but I'm no bodywork man and I've never attempted glassing.
I do have plenty of sheet metal to form a duct though. I'll do that eventually.
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Old 08-08-2010, 01:40 AM   #7
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duct tape fixes everything....

sorry it was waiting to come out....
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Old 08-08-2010, 09:13 AM   #8
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Yes some thin Alum and cut to fit and weld it to the IC , When I make these I use cardboard and cut everything to fit then lay that on the alum , cut and weld to IC

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Old 08-08-2010, 09:15 AM   #9
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Quote:
Originally Posted by ZX5_Wombat View Post
I really like the look of the blacked out bumpers, did you use gloss, matte, clear? Good job on having that trim along the cuts, looks really clean
It's satin black (matte). I don't typically use glaoss on anything.

Quote:
Originally Posted by mikebontoft View Post
still looks damn "sleeper" to me..... especially to someone who doesn't own a focus. to me that FMIC looks like a condenser unit too, making it even better

glad to see a blacked out one like that though.....I wanted to do it when I went different engine and boost but wasn't sure if I could. did you paint the intercooler or did it just come like that? looks awesome.
The intercooler came painted black, but I've since resprayed it over the years as the paint chips off.
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Old 10-18-2010, 11:32 AM   #10
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Update!
Before:
Outside temp: 60*F
Idle temp: 84*F
Max temp: 126*F

After
Outside temp: 60*F
Idle temp: 66*F
Max temp: 116*F

Max intake air temps dropped from 126*F to 116*F in the 1/4 mile, is down to 84*F by the end of the 1/4 mile runout, and 66*F by the time I picked up my timeslip.

Changes:
- Opened bumper 1.5"
- Boxed in intercooler
- Wrapped ambient pipe with reflective heat tape
- Made front air duct with 1.25" tube running to air filter

I had also made a heat shield for my air filter.
Logs showed no improvement using the filter heat shield so it's been removed.

This is an IHI RHB52 turbo with a 16T compressor wheel upgrade @ 11psi.
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