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  1. #1
    FEP Power Member SchoolBoy's Avatar
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    Default My SVO FMIC R&D project

    Ok guys since forced4 went under taking his front mount intercooler kit with him and finding a complete spearco kit is a PIA I have decided its time to create a new system. Yes I know Stinger makes a good quality, wonderfully priced kit, but I'm not a fan of the amount of pipe he uses.
    So the goals for this project are:
    -keep the cost under a grand
    -retain the A/C
    -shortest amount of pipe possible
    -NO cutting of the car
    -Come up with a workable kit
    -adapt for the turbo GT/RS cars

    To accomplish this a narrowed radiator had to be sorced. Alot of aftermarket radiator are listed as being 19" tall but then they have another inch on top of that for the filler neck. A random google search yielded mention of Ron Davis Racing Radiators which are USA made in arizona. This proved to be exactly what I needed. The radiator I ordered from him is his 19x26x3" ford style 2 core, which should give me 3.5" of clearance from end tank to the core support.

    I also sorced a rather unique 6x22x3.5" intercooler and its in the mail now.

    As for piping I am planing on having sections of aluminum tube tig'd up.
    Total pipe should consist of:
    1x 45* bend,
    1x 90* bend,
    1x "S-Bend"
    and some straight pieces.

    Some silicone couplers/bends will be needed:
    1x 3"-2.5" coupler,
    1x 2.25"-2.5" 90* coupler,
    2x 2.5" 90* couplers.

    Parts I know that will need to be fabracated are:
    -a/c condencer relocation brakets,
    -intercooler brackets,
    -one lower radiator bracket,
    -a one piece upper radiator bracket.

    -------------------------------------------------------------------------


    Now all that being said, the radiator showed up today and its a impressive part, very nice welds! Two things to mention is that the lower hose neck is pointed inward ever so slightly, I don't see this being an issue but we will see. Also since this is a "racing" radiator it has NO drain plug, if you want one order it with one.

    Pics are below.

    svo rad by capri_nut82, on Flickr

    svo rad2 by capri_nut82, on Flickr







    ************************************************** ************************************************** *******
    Project completion update


    Ok ladies and gentleman, after completing this project I realized that this is NOT something I am willing to kit out. There are way to many brackets to make and custom fitting to do. There for I will give up my parts list and any pointers I have.


    *Project materials list and sources:

    - From RonDavisradiators.com 623-877-5000
    -- Order the 1S-26193F stock car radiator. Be sure to have the inlet and outlet diameters changed to 1 1/4 inlet, and 1 1/2 outlets. Also the radiator does NOT come with a drain. If you want one order it with one. All of this will cost extra.
    --Also if you do the bypass like me order 6" of 1" aluminum bead rolled pipe.

    - From Treadstoneperformance.com 888-789-4586
    -- Oder the TR62 intercooler. But when you order it, order it with the small end tank that has the inlet at the bottom flipped over. This will cost extra....

    ----- This is how treadstone sells them
    SAM_0416 by capri_nut82, on Flickr

    ----- This is what it needs to look like, notice the end tank has been flipped.
    SAM_0570 by capri_nut82, on Flickr


    -From Cxracing.com
    -- Order PIP250-AI 2.5" OD Air Intake S shape Aluminum Pipe, Mandrel Bent Polished, 2mm Thick Tube, 14" LengthP
    -- Order IP250-90-24 2.5" OD Universal Aluminum Pipe 90 Degree, 2mm Thick Tube, 24"
    -- OrderEB250-90-CAST 2.5" cast aluminum 90* elbow "this gets cut and welded onto the small endtank


    -From Siliconeintakes.com
    --Order all of the following

    1 x 2.5" silicone straight coupler black #SIL000615
    1 x Silicone reducer, 90* bend 2.5" to 2.0" black #BRE000951
    1 x Silicone reducer, 2.5" to 2.25" black #SIL000053
    1 x 2.5" silicone hump hose black #SIL000015
    1 x 2.5" silicone 90* elbow black #SIL000033
    1 x 2' mandrel bent aluminum 45* bend 2.5" #SIL000677
    2 x 2' straight aluminum pipe 2.5" #SIL000755
    1 x T-bolt clamp for 2.0" #CLA000100
    8 x T-bolt clamps for 2.5" #CLA000102
    1 x T-bolt clamp for 2.25" #CLA000101

    -From a hardware store you will need a few sheets of 6"x18" 16GA weldable steel or one big sheet

    -Need to be able to weld both aluminum and steel

    -A suitable electric fan "Edit" I went with a Spal IX-30102049 with a 40amp fuse and relay.

    -Hard foam pad or rubber for the padded part of the radiator brackets

    -Also for please view this thread http://vb.foureyedpride.com/showthre...d-Bypass-Valve to see how I dealt with compressor surge and boost creep by installing a bypass valve and electronic boost controller.
    Attached Images Attached Images  
    Last edited by SchoolBoy; 01-23-2018 at 12:30 PM.
    If you blink at the end of the straight away you'll miss the twisties and what fun would that be!
    1982 Capri RS 5.0L
    Suspension Build http://vb.foureyedpride.com/showthre...tion-and-Build
    1985 SVO 2A & leather.
    Motor Build http://vb.foureyedpride.com/showthread.php?t=63505
    Dyno stats and exhaust install http://vb.foureyedpride.com/showthre...Dyno-d-finally
    My FMIC build http://vb.foureyedpride.com/showthre...-amp-D-project
    Electronic boost controller and bypass valve
    http://vb.foureyedpride.com/showthre...d-Bypass-Valve
    Opperation SVO Tunes http://vb.foureyedpride.com/showthre...51#post1148551

  2. #2

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    Sounds like an awsome plan.i actually have a stinger style fmic that i bought off ebay.i just need to get the pipping.i will be following this project closely.good luck with your project.cant wait to see the finished product. Lots of pics please. Chad

  3. #3

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    Nice looking forward to this too. Make sure to document everything - part #'s and all please!!!!!!!!

  4. #4
    FEP Super Member JTurbo's Avatar
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    Subscribing for future updates.
    1979 Indy Pace Car Mustang 302 / 5spd
    1982 Mustang GT T-Top 302 / 4spd
    1986 SVO Mustang - 1C

  5. #5
    FEP Power Member SchoolBoy's Avatar
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    Alright guys lets see if I can make ya drool a little bit. Below are the pics Pat_in_L.A. took of the original forced4 kit install, these have been my sorce of insperation for this project. And Yes my core will have the return pipe come back across the top of the core similar to the one pictured because of the endtank design.

    Pat_in_L.A. install-1 by capri_nut82, on Flickr

    Pat_in_L.A. install-2 by capri_nut82, on Flickr

    Pat_in_L.A. install-3 by capri_nut82, on Flickr


    I will be posting some part #'s some I will be keeping to myself for the time being. I have about 2 years of research in this and I am kinda hoping to kit the pipes and the major brackets so that all you guys have to do is order the radiator and core. This will save people alot of money on shipping. Now If I can figure out how to adapt this for the Turbo GT's and RS's guys we all can enjoy the goodness!



    I also have set a date for this and the paint job to be finished..... It must be done by August 16th for the Props and Pony's car show fundraiser. With some luck this wont turn into a mad scramble at the end.
    Last edited by SchoolBoy; 06-19-2014 at 12:12 PM.
    If you blink at the end of the straight away you'll miss the twisties and what fun would that be!
    1982 Capri RS 5.0L
    Suspension Build http://vb.foureyedpride.com/showthre...tion-and-Build
    1985 SVO 2A & leather.
    Motor Build http://vb.foureyedpride.com/showthread.php?t=63505
    Dyno stats and exhaust install http://vb.foureyedpride.com/showthre...Dyno-d-finally
    My FMIC build http://vb.foureyedpride.com/showthre...-amp-D-project
    Electronic boost controller and bypass valve
    http://vb.foureyedpride.com/showthre...d-Bypass-Valve
    Opperation SVO Tunes http://vb.foureyedpride.com/showthre...51#post1148551

  6. #6

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    Oh boy, this is getn good!..............popcorn! Looks like its gonna come out real nice.dam it! Why cant you be my neighbor! Theres nobody cool up my way! Lol. Chad

  7. #7

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    Nice project.

    I think the length of the charge piping is pretty negligible, at least in regards to performance, however.

    I'll be interested in your solution, but I went a different route when I installed the FMIC in the TBird.
    83 TC "Clone"

  8. #8
    FEP Power Member SchoolBoy's Avatar
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    Quote Originally Posted by chads84svo View Post
    Oh boy, this is getn good!..............popcorn! Looks like its gonna come out real nice.dam it! Why cant you be my neighbor! Theres nobody cool up my way! Lol. Chad
    Don't ya know the PNW is where its at!


    Quote Originally Posted by Chuck W View Post
    Nice project.

    I think the length of the charge piping is pretty negligible, at least in regards to performance, however.

    I'll be interested in your solution, but I went a different route when I installed the FMIC in the TBird.

    I agree on the turbo to intercooler pipe, but the return pipe should make a difference as I have heard of trailer hitching with stinger unit from a few people. Got any pics of your set up chuck?
    If you blink at the end of the straight away you'll miss the twisties and what fun would that be!
    1982 Capri RS 5.0L
    Suspension Build http://vb.foureyedpride.com/showthre...tion-and-Build
    1985 SVO 2A & leather.
    Motor Build http://vb.foureyedpride.com/showthread.php?t=63505
    Dyno stats and exhaust install http://vb.foureyedpride.com/showthre...Dyno-d-finally
    My FMIC build http://vb.foureyedpride.com/showthre...-amp-D-project
    Electronic boost controller and bypass valve
    http://vb.foureyedpride.com/showthre...d-Bypass-Valve
    Opperation SVO Tunes http://vb.foureyedpride.com/showthre...51#post1148551

  9. #9
    FEP Super Member mustangxtreme's Avatar
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    Nelson, I have an 83 RS just waiting to be a guinea pig.
    Dave

    If common sense was common wouldn't it just be sense?

    1983 Capri L T top 5.0 efi aod
    1983 Capri RS Turbo
    1981 Black Magic 400 c6
    93 F-250 351 5sp 4x4

  10. #10
    FEP Power Member SchoolBoy's Avatar
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    Dave if my svo unit works and you want to build one for the RS I would suggest you order and install the radiator then bring the thing to the house so we can remove the front end to install the intercooler and move the a/c condencer. Do you have A/C on the RS?
    If you blink at the end of the straight away you'll miss the twisties and what fun would that be!
    1982 Capri RS 5.0L
    Suspension Build http://vb.foureyedpride.com/showthre...tion-and-Build
    1985 SVO 2A & leather.
    Motor Build http://vb.foureyedpride.com/showthread.php?t=63505
    Dyno stats and exhaust install http://vb.foureyedpride.com/showthre...Dyno-d-finally
    My FMIC build http://vb.foureyedpride.com/showthre...-amp-D-project
    Electronic boost controller and bypass valve
    http://vb.foureyedpride.com/showthre...d-Bypass-Valve
    Opperation SVO Tunes http://vb.foureyedpride.com/showthre...51#post1148551

  11. #11

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    Quote Originally Posted by SchoolBoy View Post

    I agree on the turbo to intercooler pipe, but the return pipe should make a difference as I have heard of trailer hitching with stinger unit from a few people. Got any pics of your set up chuck?
    I never had any issues with trailer hitching.
    A couple pics from the build up.





    I could've saved a little bit on the turbo to IC piping, had I rotated the compressor housing. It didn't wind up any place that made me happy, however. Boost comes on angry and quick.
    83 TC "Clone"

  12. #12
    FEP Super Member escogt's Avatar
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    This is fun!!! Subscribing!!
    '85GT Bright Atlantic Blue
    '92LX Bimini Blue

  13. #13
    FEP Power Member SchoolBoy's Avatar
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    Nice pics chuck, I actually came real close to doing it that way.


    Escogt, just wait till you see my thread on the outside mods and dip as well....
    If you blink at the end of the straight away you'll miss the twisties and what fun would that be!
    1982 Capri RS 5.0L
    Suspension Build http://vb.foureyedpride.com/showthre...tion-and-Build
    1985 SVO 2A & leather.
    Motor Build http://vb.foureyedpride.com/showthread.php?t=63505
    Dyno stats and exhaust install http://vb.foureyedpride.com/showthre...Dyno-d-finally
    My FMIC build http://vb.foureyedpride.com/showthre...-amp-D-project
    Electronic boost controller and bypass valve
    http://vb.foureyedpride.com/showthre...d-Bypass-Valve
    Opperation SVO Tunes http://vb.foureyedpride.com/showthre...51#post1148551

  14. #14

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    Quote Originally Posted by SchoolBoy View Post
    Nice pics chuck, I actually came real close to doing it that way.
    I wanted a decent-sized core and no cutting of the body as well. I thought about the pipes on the same side route as well. In the end, this just worked out better, and made use of some of that space in the engine compartment.
    83 TC "Clone"

  15. #15

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    Chuck,great job on your intercooler set up! I like how its different than the others.very unique. Chad

  16. #16
    FEP Member BrianM's Avatar
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    Chuck where is your VAM? In the fender?
    1970 U14 Bronco
    1983 911 SC
    Sold - 1986 SVO 1D #9823

  17. #17

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    Quote Originally Posted by BrianM View Post
    Chuck where is your VAM? In the fender?
    There is no VAM, only Zuul....

    No VAM. Running MegaSquirt.
    83 TC "Clone"

  18. #18
    FEP Super Member mustangxtreme's Avatar
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    Do you have A/C on the RS?
    Yeah Baby.
    Dave

    If common sense was common wouldn't it just be sense?

    1983 Capri L T top 5.0 efi aod
    1983 Capri RS Turbo
    1981 Black Magic 400 c6
    93 F-250 351 5sp 4x4

  19. #19
    FEP Power Member SchoolBoy's Avatar
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    Quote Originally Posted by mustangxtreme View Post
    Yeah Baby.

    Ok so we will need to move it then.
    If you blink at the end of the straight away you'll miss the twisties and what fun would that be!
    1982 Capri RS 5.0L
    Suspension Build http://vb.foureyedpride.com/showthre...tion-and-Build
    1985 SVO 2A & leather.
    Motor Build http://vb.foureyedpride.com/showthread.php?t=63505
    Dyno stats and exhaust install http://vb.foureyedpride.com/showthre...Dyno-d-finally
    My FMIC build http://vb.foureyedpride.com/showthre...-amp-D-project
    Electronic boost controller and bypass valve
    http://vb.foureyedpride.com/showthre...d-Bypass-Valve
    Opperation SVO Tunes http://vb.foureyedpride.com/showthre...51#post1148551

  20. #20
    FEP Power Member SchoolBoy's Avatar
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    Ok so back on track.....

    One of my major concerns was that the radiator would not fit into any of the stock brackets. Tonight I confirmed That drivers side lower is the only one I will be using. The upper fits, but I don't want to relocate the passanger upper bracket. Instead I am planning on doing a flat pannel template to make a support plate like this that will bolt into the two stock holes.

    Radiator%20Hold%20Down by capri_nut82, on Flickr

    Now because the radiator is shorter, I need to fabricate a new lower bracket. Yes I could cut mine out and relocate it, but If I want other people to be able to do this I need a bolt in bracket. So I verified where the stock rubber isolater will sit on the radiator bottem. Then using some poster board type material I made a flat pannel template.

    SAM_0396 by capri_nut82, on Flickr

    SAM_0397 by capri_nut82, on Flickr


    SAM_0400 by capri_nut82, on Flickr

    SAM_0408 by capri_nut82, on Flickr

    SAM_0409 by capri_nut82, on Flickr

    SAM_0411 by capri_nut82, on Flickr

    SAM_0412 by capri_nut82, on Flickr

    SAM_0413 by capri_nut82, on Flickr




    Now the only thing missing when I have the real metal one made is a tab on each side extending down to go around the frame rail. I will use sheet metal screws to hold it in place.

    SAM_0414 by capri_nut82, on Flickr

    SAM_0415 by capri_nut82, on Flickr
    If you blink at the end of the straight away you'll miss the twisties and what fun would that be!
    1982 Capri RS 5.0L
    Suspension Build http://vb.foureyedpride.com/showthre...tion-and-Build
    1985 SVO 2A & leather.
    Motor Build http://vb.foureyedpride.com/showthread.php?t=63505
    Dyno stats and exhaust install http://vb.foureyedpride.com/showthre...Dyno-d-finally
    My FMIC build http://vb.foureyedpride.com/showthre...-amp-D-project
    Electronic boost controller and bypass valve
    http://vb.foureyedpride.com/showthre...d-Bypass-Valve
    Opperation SVO Tunes http://vb.foureyedpride.com/showthre...51#post1148551

  21. #21

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    We had used a Volvo inter cooler with a ranger radiator. but didn't keep the AC
    1983 Capri RS Turbo
    1986 Bronco 351ho
    VP Berks County Mustang Car Club
    http://www.cardomain.com/ride/2462250

  22. #22
    FEP Power Member SchoolBoy's Avatar
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    Right so I made some progress today, but only after I realized that the first pattern I made wasn't going to work. I made that using the rubber support from the drivers side of the radiator which is unique to that side. So I started all over this time using the passanger side off the svo. Once the paper template was done I made one out of aluminum. I beat the crap out of thing on dads vice for 3hrs before I realized I had the perfect sized hickory block to tap the sides into position.


    IMG_20140626_144917_739 by capri_nut82, on Flickr

    SAM_0420 by capri_nut82, on Flickr

    SAM_0421 by capri_nut82, on Flickr

    SAM_0422 by capri_nut82, on Flickr

    SAM_0423 by capri_nut82, on Flickr

    SAM_0424 by capri_nut82, on Flickr

    SAM_0425 by capri_nut82, on Flickr



    And the intercooler core showed up today after doing some measuring I am afraid its not going to fit. I will be calling a friend tomorrow to see If I can test fit it on one of his cars that has the nose off. I am not taking the nose off my svo unless I am fairly sure this is going to work. One of my possible solutions is to cut he lower connector off and have a 90* pipe welded on at a 45* angle up ward. Either way if this doesn't fit there is not enough time to replace/fab up a replacement in time to make the show.

    SAM_0416 by capri_nut82, on Flickr

    SAM_0417 by capri_nut82, on Flickr

    SAM_0418 by capri_nut82, on Flickr
    If you blink at the end of the straight away you'll miss the twisties and what fun would that be!
    1982 Capri RS 5.0L
    Suspension Build http://vb.foureyedpride.com/showthre...tion-and-Build
    1985 SVO 2A & leather.
    Motor Build http://vb.foureyedpride.com/showthread.php?t=63505
    Dyno stats and exhaust install http://vb.foureyedpride.com/showthre...Dyno-d-finally
    My FMIC build http://vb.foureyedpride.com/showthre...-amp-D-project
    Electronic boost controller and bypass valve
    http://vb.foureyedpride.com/showthre...d-Bypass-Valve
    Opperation SVO Tunes http://vb.foureyedpride.com/showthre...51#post1148551

  23. #23
    FEP Power Member SchoolBoy's Avatar
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    Well I couldn't find a car local that was apart so I attacked mine today. The front end came off really easy I could reach all the bolt no problem. But man am I in for some work......

    SAM_0426 by capri_nut82, on Flickr

    SAM_0427 by capri_nut82, on Flickr

    SAM_0429 by capri_nut82, on Flickr

    SAM_0430 by capri_nut82, on Flickr




    Here you can see how much clearance the new radiator gives me....

    SAM_0431 by capri_nut82, on Flickr

    SAM_0432 by capri_nut82, on Flickr



    Notice the A/C condenser has been moved back. To do this just undo the 4 brackets 2 on top, 2 on the bottom. Will need to make brackets to hold it there though. Also the radiator needs to be moved back at least an inch now as well. The power steering cooler is either going to get relocated or we are going to bend up a new one as its just pipe.

    SAM_0433 by capri_nut82, on Flickr
    If you blink at the end of the straight away you'll miss the twisties and what fun would that be!
    1982 Capri RS 5.0L
    Suspension Build http://vb.foureyedpride.com/showthre...tion-and-Build
    1985 SVO 2A & leather.
    Motor Build http://vb.foureyedpride.com/showthread.php?t=63505
    Dyno stats and exhaust install http://vb.foureyedpride.com/showthre...Dyno-d-finally
    My FMIC build http://vb.foureyedpride.com/showthre...-amp-D-project
    Electronic boost controller and bypass valve
    http://vb.foureyedpride.com/showthre...d-Bypass-Valve
    Opperation SVO Tunes http://vb.foureyedpride.com/showthre...51#post1148551

  24. #24
    FEP Super Member mustangxtreme's Avatar
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    Nelson, I would use an aftermarket power steering cooler. The factory ones don't do the greatest job during spirited driving.
    Dave

    If common sense was common wouldn't it just be sense?

    1983 Capri L T top 5.0 efi aod
    1983 Capri RS Turbo
    1981 Black Magic 400 c6
    93 F-250 351 5sp 4x4

  25. #25
    FEP Power Member SchoolBoy's Avatar
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    Things have been a bit slow around here waiting on parts to show up so I took a few minutes to play with the idea of making a gauge pod for the dash. It would be big enough for two 2 1/6" gauges. The first one I already have which is the innovate wideband. The second is a high quality digital dual gauge reading both the in and out air temps for the intercooler that I need to order. This Is a really ruff Idea.....


    SAM_0437 by capri_nut82, on Flickr

    SAM_0436 by capri_nut82, on Flickr

    SAM_0434 by capri_nut82, on Flickr
    If you blink at the end of the straight away you'll miss the twisties and what fun would that be!
    1982 Capri RS 5.0L
    Suspension Build http://vb.foureyedpride.com/showthre...tion-and-Build
    1985 SVO 2A & leather.
    Motor Build http://vb.foureyedpride.com/showthread.php?t=63505
    Dyno stats and exhaust install http://vb.foureyedpride.com/showthre...Dyno-d-finally
    My FMIC build http://vb.foureyedpride.com/showthre...-amp-D-project
    Electronic boost controller and bypass valve
    http://vb.foureyedpride.com/showthre...d-Bypass-Valve
    Opperation SVO Tunes http://vb.foureyedpride.com/showthre...51#post1148551

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