Custom FMIC & Downpipe Project

[firdausasri]

Hi Guys,

It's been awhile since I last pop in here...:)

I just would like to share my completed project on custom FMIC and catless downpipe done by local exhaust shop. So here’s the list:-

1. Custom FMIC – Used Evo3 intercooler, all-new custom piping from turbo to intercooler and intercooler to manifold, plus relocation of DV.
2. Open-pod K&N filter with custom heat-shield.
3. Custom 2.5” catless downpipe.

IMHO, they crew did awesome touches on every single thing making what I’ve paid twice the bargain! No kidding! The pictures below are self-explaining but I forgot to take with engine cover on...will do it soon :)

As for the drives, well, what I can tell though there’s a slight (very slight) lag of 300-500rpm for the turbo to spools but once the revs past 3k all the way to 5.5k, the car pulls with fatter torque figures and more rush feeling at high revs. I just can’t wait to get the whole thing settled down for dyno exercise work:)

http://www.vwwatercooled.com.au/forums/images/imported/2011/07/img_phu1256_fmicanddownpipe_02-1.jpg
The sensor was 'raised' an inch to be stealthy against the CEL

http://www.vwwatercooled.com.au/forums/images/imported/2011/07/img_phu1256_fmicanddownpipe_03-1.jpg
Some adjustment on the inlet/outlet needed, if Evo 7/8 intercooler of the same size, it would be ideal

http://4.bp.blogspot.com/-idFoM68OQIs/ThhgyOgx6RI/AAAAAAAABH/oSdbM8VpEq0/s800/img_phu1256_fmicanddownpipe_05.jpg
They've relocated the DV for better cooling

http://www.vwwatercooled.com.au/forums/images/imported/2011/07/img_phu1256_fmicanddownpipe_06-1.jpg
Amazing work on custom heatshield

http://www.vwwatercooled.com.au/forums/images/imported/2011/07/img_phu1256_fmicanddownpipe_07-1.jpg
The old Evo 3 intercooler seems to be working well which defies its age

http://www.vwwatercooled.com.au/forums/images/imported/2011/07/img_phu1256_fmicanddownpipe_08-1.jpg
The guy managed to make a hole when I didn't think it can be done

http://www.vwwatercooled.com.au/forums/images/imported/2011/07/img_phu1256_fmicanddownpipe_09-1.jpg
Got to love the welds done by the Myanmar national staff, reminding me of seeing these things in the US

http://www.vwwatercooled.com.au/forums/images/imported/2011/07/img_phu1256_fmicanddownpipe_11-1.jpg
Initially I couldn't flat on the throttle because they've forgotten to include the boost sensor but all is well :)

[dood9n3]

That looks fantastic, awesome job done here

[firdausasri]

Thanks :)

Actually I would have wanted Forge FMIC with APR downpipe but the escalated highness of shipping cost and 40% of tax is just killing me in the end. Hence the reason why I opted for local fabrication of these :)

Anyway, here's the finished product with the engine cover on

http://www.vwwatercooled.com.au/forums/images/imported/2011/07/img_phu1256_fmicanddownpipe_12-1.jpg

[vwthunder]

Looks good
Makes the standard engine bay look a whole lot different, and im sure it works well too

[firdausasri]

Yeah it does actually works where I didn't notice a flinch of lag-ness courtesy of the new 500x300x65 intercooler with new piping routes. Unfortunately, my AFR is 13.5 lean from 4k rpm onwards...

[dood9n3]

What causes the lean AFR? too big cooler?

[DNA Tuning]

Nice one; I am of the opinion that low IAT's is more desirable than a slightly quicker boost response, especially when we're talking about K03's here that spool so quickly. They do generate alot of heat however, esp at Stage 2/2+ levels so cooling the air charge down makes a huge difference.

Great work; nice to see people trying out custom setups.

[firdausasri]

dood9n3,

I'm still waiting for TurboSmart FPR adapter before fitting it in, it might be stock 3 bar FPR is not enough. Will keep you guys updated.

John,

Yup, I honestly agree. Even on bigger intercooler size, I didn't feel much lag as the piping diameter being limited to 2" from turbo towards intercooler. But difference during the day especially in Malaysia is very significant. Unfortunately, I can't really full throttle now pending some fueling and remap.