My radiator and intercooler have been fabricated and installed with all the pipework made as well. I got both the intercooler and radiator custom made in China, considering the ridiculous prices I was quoted locally here in Perth and and I am quite happy with the quality end product and of course the price
The radiator uses the factory Starlet lower rubber mounts in a bracket that's attached to the front subframe bar (the one that joins to the two spars together). I had two 6mm diameter pins welded onto the underside of the radiator to slot into these mounts.
The upper mount is a simple bracket with a grommet for vibration isolation
The rubber pipes are easy. The lower pipe is actually the factory one in a reversed direction and trimmed! This is the only pic I have of it - from my mock up from a long time ago.
The upper hose is a tight squeeze past the thermofan shroud so I have had to use three bends from various 30mm ID hoses to get something that works. I have had to trim the shroud slightly and still have to make a small bracket/clamp that will hold the hose closer to the engine and stop it from rubbing on the shroud.
I have installed an adapter which I will use for the temperature gauge thermocouple.
The intercooler is where my conversion differs from everybody elses so far on ausmini. I chose to utilise an air-to-air IC in much more discrete front mounted position behind the grille. The 60mm thick IC (and slightly larger core volume than the factory IC) will be mounted behind the front grille and eventually painted black. There are two bolts holding the IC onto the bumper and a top bracket with some more grommets (to allow for some movement since it's pipework is very close to the turb outlet - the IC can actually move up to ~4mm as the engine revs/rocks)
The pipework has also been completed in 2"/51mm mild steel. I can hear the people now... "why didn't you make it from aluminium?". Well simply because my budget is currently quite tight and can't justify the extra cost of ally and TIG work when I can weld steel myself. The pipes will ultimately be blasted, painted (and wrapped?). There is a reducer pre-turbo since the turbo inlet is only 40mm diameter.
This pic shows the (fully welded) airbox to turbo pipe and shows the 51mm-40mm silicon reducer for the turbo inlet
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-Alan
I blame my dad for my love of minis. I think I was conceived in the back seat of one
I also blame my Dad for me being 6' 1" - not really the optimum height for driving a Mini.