The problem i have is the FMIC i have is a small long one that i wish to locate the lower bumper of the G...

Moving the std rad/fan setup forward leaning is fowling the horn and i would also be worried about clearance for the charger, although the charger does sit quite close to the slam panel as it is...

So i'm thinking cheapest option is to remove the horn and relocate that and lean the rad forward to clear the charger or does anyone know a decent fan setup i could use to rid myself of the chunky std cowling?

Looks like a few new holes and the setup should look quite neat!

Edited 9 July, 200719 yr by DaveG40

I'd just move the horn, easy and pretty much free too

yeah I moved my horn to fit my IC and rad etc.... It lives under the plastic tray thingy now.

Blimey Dave, if you think its tight on a mk3 you wanna try getting an Eaton, large FMIC, oil cooler, rad and fan in a mk2!

Tighter than a nuns Jack and Danny (apparently!)

Righto i have been fettling last night with some success although my neibours are getting annoyed with my car in pieces in the flat car park...lol

I managed to drain the radiator and shift it toward the charger - then leant forward with the horn removed it is just touching the metal below the bonnet catch...

This did however give me enough room to have the intercooler and pipework where they need to be...

So i collected a metal grinder, a drill and an extension lead to begin the fun again tonight - hopefully trimming the lower front valance and slightly modifying the metal below the bonnet catch for half an inch clearance or so should ensure the rad doesn't foul - redrill the holes for the rad to sit on and chop out some of the valance to allow the cooler to sit further back to get the bumper fitted...

I am sure i will slightly modify the fan cowling aswell as i am worried about the charger fowling it...

Then i will need to make up some solid brackets as i dont wan't to drill the car anymore than i have to - using brackets to secure the radiator and then again something to hold the intercooler in place aswell...

I was quite pleased with the progress - although i have damaged the rad fins a little from playing and know that some hard graft is required tonight - as mentioned it should look quite neat when finished...

As i'll be cutting - ill plumb everything then pull it all off the paint the bare metal as it will rust if i leave it bare!

Anyone got any pics to show their std rad mounting brackets or solutions with FMIC'S?

You can buy slimline fans to use instead of the standard fan and cowling, and iirc they are more powerful than the standard fan on a G40. This is what I've got on mine anyway and has made the relocating of my radiator higher up and towards the passenger side of the car a lot easier than it would have been with a standard fan and cowling.

I had to modify my bonnet mechanism slightly as I had the problem of it fowling (and hence mashing) the radiator, with a bit of fiddling and a different bolt it now works a treat :-D

Thanks Sal,

I am working on a tight budget for now - i know not the best thing to do but with bills to pay it seems impossible to fund anything for the car at the moment...

I would be interested in the info for the slimline fan and connection issues - where to buy how much etc....

If i can retain the std items with modification then it should be OK - using a slimline fan would be a good idea though when some pennies come in!

Dave

I've managed to use the normal fan and cowling on mine. Although I did make a new bottom cross member and new mounts for the rad, also had to make that pretty strong because there is an extra engine mount there too.

It's all a tight-ish fit and various bits of metal needed chopping and some welding but it's pretty good now.

I've managed to use the normal fan and cowling on mine. Although I did make a new bottom cross member and new mounts for the rad, also had to make that pretty strong because there is an extra engine mount there too.

It's all a tight-ish fit and various bits of metal needed chopping and some welding but it's pretty good now.

This has to be one of the most productive threads on clubpolo for me so far - as this FMIC is a proper custom fit and as most coolers are different every fitting is unique - so the advice although specific to individual application is very helpful - a huge thanks to you all...

I am thinking about taking some pictures as i modify the valance later and cut the horn bracket etc - usual modifications required to fit an FMIC diary style....

If PSD do sell a slimline fan i wonder how much that would be roughly?

I would imagine Steve would be able to get you a slimline fan but to be honest you can buy them from any car tuning/motorsport place.

Any particular recommendations?

Does it need to run @ a certain speed etc...???

I'll add this to the list with my oil cooler on - for when a bonus or something comes in....

RallyDesign, Demon Tweeks, Merlin Motorsport, Peter Lloyd Rallying, Burton Power......to name a few, there will be about a million places if you do a couple of google searches.

I guess they're all a similar speed you just need to get a 12v one, I think 12" diameter is best too.

I guess i would need to mount and fabricate some type of brackets for this fan also which is something that would need addressing....

As mentioned i am skint so will get this done using the std stuff for now - but thanks for the product info - i will keep a copy of this thread in the faviroutes folder....

Dave

I've stuck with stock fan & rad too. Don't see the point in replacing it when there's nothing wrong with it. Maybe a different story after I've done a track day or two though, if heat becomes a problem then I'll do something about it. At least I don't have one of these horrible heat-producing turbo thingies though

I've stuck with stock fan & rad too. Don't see the point in replacing it when there's nothing wrong with it. Maybe a different story after I've done a track day or two though, if heat becomes a problem then I'll do something about it. At least I don't have one of these horrible heat-producing turbo thingies though

There is still a few G40's knocking about with enough power to show them up....

Any idea's on what to use to cut the lower valance? Hack saw? Metal Grinder to it?

Need to square off front lip to sit the cooler back further and the bumper fits....

Not much progress made tonight - waiting on a hacksaw and drill bits....

Only managed to remove the lower valance and give it a clean in the flat....but better than nothing!

Edited 5 June, 200719 yr by DaveG40

what do you mean by lower valance? do you mean the bumper iron? I just used an angle grinder to cut anything with anyway. You can get really thin "plasma" cutting discs which are good for cutting metal with.

what do you mean by lower valance? do you mean the bumper iron? I just used an angle grinder to cut anything with anyway. You can get really thin "plasma" cutting discs which are good for cutting metal with.

Sorry - i am referring to the lower cross member that the rad and intercooler normally sit on...

This is currently off the car to "modify" for the intercooler to be fitted...

So attacking it with an angle grinder is the best bet then?

LOL

I see, yeah just go at it with a grinder. Although you could probabyl cut through that crappy bit of tin with a pair of scissors

I see, yeah just go at it with a grinder. Although you could probabyl cut through that crappy bit of tin with a pair of scissors

haha so funny because it's so true!

That bit of "tin" metal is actually stronger than i thought - and while i wanted to attack it with a grinder - i felt safer using a big saw thing...

It has a blue blade and is about 3 times the size of a hack saw and sliced through this metal like butter...

I chopped the square required out of the front of the panel last night and then had a million other things to do but progress again has been made...

I am going to take it to the grinder tonight to tidy all of my cutting edges and make it look neat - then test fit the rad and get the rad holes drilled and work out the brackets i will need....

It is Thurday now - has taken me nearly every evening this week to make this much progress - but if i do it in calm - thought out bits - the job will be done to a higher standard...

No pics yet - waiting on grinding to be finished...

Dave

Last night the grinder came out and the section removed has been tidied to a good standard...

I then fitted the IC with a zip tie (mock up) for now and fitted the front bumper which fits - YAY

I then removed the lot and Drilled the new rad mounting holes...

I gave up there as it was a long day - will be modding the cowling and fitting the rad first then fitting everything else around this...

Saturday should see the rad and fan in with intercooler fitted and held securely only awaiting some joiner pipes...!!!!

Pics to follow soon...

Dave

Did you get your trial fit done?

Sorry haven't updated this in a little while!

Indeed i did get a trial fit done - the intercooler section needed a little more trimmed out and then i fitted them all at the same time - rad, cooler and bumper - which is now going over the cooler but still not sitting flush...

I have some rad brackets to complete aswell - and sort the horn bracket still aswell...

All in all it isn't "easy" and is taking me a while but i have lots to do and little time every evening after work...

I need some pipe also to finish the cooler plumbing once it is bolted to the car and then she should be ready for painting the install ready for its final fitting!

Dave

UPDATE!!!!!

LOL - Sorry it has been a little while - i'm not lazy I just hate working in poor weather!

Last night I decided I would go down to the car - and remove the trial fit work and cut out the section just below the bonnet catch.

I then hammered the sections in so that they look neat and tidy and started fettling my front bumper to make room for the IC.

The bumper needed two sections cut for the end tanks of the IC - using a blue blade i managed a strangely for me neat job and was quite pleased.

After this progress I thought - why not make the second and last radiator bracket now the rad can be positioned correctly and trial fitted - so I did and the brackets are now complete apart from a trim and a spray - also need a couple of split pins for peace of mind.

So that leaves me a very happy chappy - 2 brackets ad some IC piping and the job is done - I honestly am so pleased!

Anyway - a trip later to B&Q will see me with some metal for the IC brackets hopefully but there was a slight problem once the rad was fitted....

The top pipe for the rad is now ever so slightly too short but isn't a biggy - and is easily sorted.

Anyway for now - sorry to bore you all - pipework and brackets are en route along with some hammerite and then she is done! wooohooo

UPDATES AHOY

Intercooler is now FITTED! Brackets and Piping are Done! Just need to remove it all for painting soon....

Here is some bad pics....(lol at my dodgy camera skills and the dark light!)

Bumper fitted:

Closer shot of how the IC looks (kind of - need a better pic)

Charger to IC Join:

Mmmmmmmmmmmm 80 Degree bend making things nice and simple (needs polishing / buffing) :

And finally a shot showing the pipe bend used and kind of the radiator reloaction...

I need more pics in the light and to re-attach and re-fill the coolant system, extend a rad pipe and buy a couple more jubilee's to get this properly connected.

Though I am chuffed!

Let me know what you think - Dave