Hi.

After making up variety of pipework for the 205 & 185 , I thought it would be a good idea to construct some jigs.









This could be useful if you have a 185, 205 that needs intercooler piping..

Its still in experimental stage, have just produced the 1st pipe from the main jig, I still have a fair bit to sort out.
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Black UK 96 205 shed with heater full on telemetry.

project six million dollar 185, faster, stronger, lighter than before.

Yes please!

Let me know when you want to test fit lol. I'm free all day at the moment

(At least I will be when this [bleeeeepeeeeepeeeeeep] wheelbearing replacement is done)

Jon,

Good work! To be honest I'm amazed that no one has done this before as there must be loads of people out there who would like to buy a well designed and fabricated FMIC kit for their 185/205. Every FMIC I've seen seems to feature bespoke plumbing (and core). Even the two Fennies ST205's were different and no pattern exists (I've asked!)

Is there any chance you could sketch out and post a plumbing diagram? Also, I hope you are clocking the turbo so that the outlet is at the bottom rather than the top?

Cheers,

_________________
Don
GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

you need a press for wheel bearing steve.


A simple drawing

_________________
Black UK 96 205 shed with heater full on telemetry.

project six million dollar 185, faster, stronger, lighter than before.

I wish all I needed was a press

I'm bogged down trying to solve a prior crime

It turns out that mine has had a bearing failure at some time in the past. One og the races has spun on the stub shaft releiving it of a little bit of metal (about 8 thou....). Currently investigating the Loctite product catalog to find a bearing location goop to fix this. Failing that I might have to get the shaft machined and phospher bronze sleeve it

Oh for a simple fix lol

Retro style pipework running on the outside of the wing...
I like it!!!!

But on a serious note how big a job is it to run it through the wheel arch???? Much cutting etc????

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ST205 WRC #0002249

No! A little easier out, say removing 3mm of material from behind the fusebox, and that's it!

_________________
Kris
95 ST205 - slept for 10 years, now waking up...
Avensis
http://www.gtfours.co.uk
_______________________________________
Turbocharging - the replacement for displacement

Thanks Jon, I like the pipe runs. Who's the ST205 FMIC guinea pig, Mr Potato Head?

_________________
Don
GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

yeh I think mr Potato head has been in cahoots with datajon on a couple of occasions - Sounds like they have formulated a nice setup.

I assume the pipework is to be 2.5" guys? Any idea on cost for another set of pipes or 4?

_________________
JP
GT4DC Treasurer

Grey St185 RC
Silver BMW E46 M3
Multicolour yawn Honda VFR400
Silver Honda Civic Type-R

I reckon the best plan is to prototype the initial design and once all the bugs have been ironed out then give the green light to a production run. IMHO I don't think it would be too clever to lay down a production run until the prototype has been thoroughly tested.

I'm assuming that the hard pipe sections can be universal and everyone will be running clocked turbos. People may elect to fit different intercooler rads but hopefully the connections to the end tanks will be in much the same place. Any slight variations could then be accomodated in the flexi hose connectors.

On the detail side it would be nice if the pipes could have rolled ends so that the hose joiners don't blow off. Owens are selling special spring loaded jubilee/mikalor style clips to hold flexi hose onto the hard pipes even under high boost pressures. They claim the clips are used by most of the WRC teams.

_________________
Don
GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

Yes. Based on your calculations and requirements it appears that 2.5" pipework is ideal.


Agreed. Testing is due to commence shortly, results and improvements to be fed back and incorporated into the final design...


Yes


Yes again! imho it is madness not to clock the turbo. This allows a more ideal setup and better pipework routing.


All joints that have a Silicon hose will have hose retainers. Aiming for a well built reliable bit of kit, one that throws off hoses is not on the agenda!


Stainless Mikalor clips are the way forward imho...

More info to follow once any bugs have been ironed out and all feedback incorporated into the final design...

_________________
Kris
95 ST205 - slept for 10 years, now waking up...
Avensis
http://www.gtfours.co.uk
_______________________________________
Turbocharging - the replacement for displacement

Good man! ... this is just what the doctor ordered ...and just in case you were wondering Valentino Rossi is not a closet GT-Four driver AFAIK

_________________
Don
GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

" this is just what the doctor ordered Very Happy ...and just in case you were wondering Valentino Rossi is not a closet GT-Four driver AFAIK"

He did drive one tho.... RAC Rally..199??? maybe00, 01
Unfortunately if you blinked you missed him if I recall.

Also does this mean the most sort after accessory.. for yer track car this year is gonna be a FMIC !! and if so how much power will it loose over the standard 205 set-up? 165s & 185s accepted Yet to be fully convienced, is not an oil cooler a better for a mid-power (say 350-400) option

Sorry ever the non tech..

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Le Latern Rouge...300ish bhp 13.8 1/4
more to come... gonna love track days.

I'd go out on a limb and say you should make a little more power since the air entering the engine should be a little cooler?


It has been proven that for higher output cars the inlet temps start to rocket once you open the car up for sustained periods of time.

From my personal point of view I think a FMIC is one way towards reliable higher power levels.

As good as the 205 IC system is, it cannot keep the intake temps in check - ask Don! iirc his WI pick up was suffering problems and hence his WI system was running dry now and again, in these short time intervals the intake temps rocketed to 70+Deg C

An engine oil cooler is also a good item to install. Even on a stock car the temps on track rocket. Keeping these in check with a good oil cooler seems a sensible move in my book

_________________
Kris
95 ST205 - slept for 10 years, now waking up...
Avensis
http://www.gtfours.co.uk
_______________________________________
Turbocharging - the replacement for displacement

In my ever so humble opinion

I would rate an oil cooler above a FMIC

The ECU will take steps to deal with raised inlet temps (allbeit at the expense of power)
There is nothing it can do about oil temp and overheated oil will kill your engine more dead than a bit of det

As I just wrote in the track mods thread, I would not consider the Four as anything more than a 5 lap "sprint" machine until equipped with enhanced oil, water and charge cooling systems.

Not quite ready for 24H fun out of the box