The Ultimate Mi Radiator To Inlet Clearance Thread

[de Noir 0]

Here is how I ultimately solved the radiator to inlet manifold clearance issue on my Mi conversion:

 

 

It's all about modding the fan cowl.

 

Everything that is popping out of the imagined (and real) fan housing surround plain needs to be removed.

Simplified, you cut out the yellow marked areas and ensure everything is level:

 

 

 

I have used the jigsaw to cut the fan cowl.

When you're done, it shoud look this way (pictured right):

 

 

 

Cutting out that amount od plastic is adding unwanted structural weakness to the fan cowl.

This is fixed by welding-back some previously cut-out material, at the olive coloured positions.

Mounting bracked can be strengthened by adding further cut-out material from below.

Existing mounting holes can be drilled to oval, for better adjustment (marked green):

 

 

 

 

Standard vs modded fancowl pictured below:

The whole structure is slimmer and has a fair bit more openings.

Meaning more airflow and better cooling.

Fan is not pictured here, but fits perfectly, leaving enough clearance to radiator.

 

 

 

 

Finally, radiator is inserted into the fan cowl standard way.

Radiator holder springs can also be shortened and fitted to their standard position.

The whole assembly occupies their regular position...

 

 

 

 

 

...leaving about 2cm clearance between intake manifold and radiator:

 

 

 

 

The finished article in my project thread soon!

Cheers!

 

[blessed6383 0]

not bad but how flexible is it now with the loss? am considering doing mine

[CosKev 16]

Moved the rad forward slightly on my 309,with twin slim line fans

 

Didn't really need to as you will see with the pics the clearance between engine and rad is now excellent

 

 

 

[de Noir 0]

Rad clearance on 309 isn't really an issue.

 

 

 

not bad but how flexible is it now with the loss? am considering doing mine

 

 

Actually, it's not that bad without any strengthening mods, but I prefer not to leave it that way.

Welding plastic plates on 'olive' positions adds stiffness, as standard reinforcement fins are directly underneath.

[Cameron 16]

 

 

 

Simple.

[Baz 421]

Simple.

 

Not if you want to keep it reasonably standard/OE though.

[jackherer 543]

Simple.

 

Its not quite that simple, how are you attaching the grill? Also the slam panel will need reinforcing if you are still using the bonnet catch and not pins. The fan cowling has quite a few separate functions, not all of them immediately obvious.

[24seven 104]

I must have a weird alien super fat radiator. Even after chopping the hell out of the cowling it's still sat against the manifold. It's just a standard replacement one, can't remember the brand. That said it does keep the water temps a lot cooler than the ally Nissens one that used to be in there, literally the only time it ever goes above the half way mark is when sat in traffic.

[welshpug 1,621]

I must have a weird alien super fat radiator.

 

aka a TD rad, end tanks same as the gti/diesel but a much thicker core

[Cameron 16]

Not if you want to keep it reasonably standard/OE though.

 

 

Its not quite that simple, how are you attaching the grill? Also the slam panel will need reinforcing if you are still using the bonnet catch and not pins. The fan cowling has quite a few separate functions, not all of them immediately obvious.

 

You're right actually, it isn't that simple.

 

Slam panel is fine though isn't it? It just bolts to the bulkhead, or have I just been missing bolts for a long time?

 

Edit: Actually now that I think of it the cowling is bolted to the slap panel, mine was lowered originally. Man it's been way too long since I had a standard GTI.

Edited March 30, 2010 by Cameron

[jackherer 543]

The slam panel flexes if its not supported by the fan cowling and the bonnet wont close properly.

[welshpug 1,621]

The bonnet also pops open at about 70 mph with an un-secured/strengthened slam panel

[Cameron 16]

My bonnet popped open at 30mph, but that was more because the catch was nackered.

[blessed6383 0]

shhhhhhhhhhhhhhh dont talk about the bonnet flying open it scares the crap out of me had it happen on my old bmw at around 60ish and the result was a foot shorter bmw (proper compact) lmfao mind you best thing that ever happen as bought another pug with the comp money lol

[matthewm 1]

Set of pins will put your mind at ease, make sure you keep the bonnet stay though, that way if - for example - you were stupid enough to forget to do the pins up, it at least stops the bonnet from hitting the screen - so I've heard

[Cameron 16]

Doesn't stop this from happening though..

 

 

[de Noir 0]

 

 

Simple.

 

 

 

I have tried to avoid this at all costs!

Nice framework, but do not like the shell cutting idea at all.

[Cameron 16]

Fair enough, I know most people won't want to be cutting bits out of their 205's.. I remember how difficult my first cut was!

[blessed6383 0]

OUCH

[blessed6383 0]

did mine last night is looking much slimmer now has a spare one so wasn't too bothered if i made a balls up lol looks pretty damn good tho

[taylorspug 7]

Set of pins will put your mind at ease, make sure you keep the bonnet stay though, that way if - for example - you were stupid enough to forget to do the pins up, it at least stops the bonnet from hitting the screen - so I've heard

 

Not everyone wants a set of bonnet pins though, they look crap on anything but a proper track/race car.

 

The fan cowling guide MH has put up is spot on, its exactly the same as ive done them in the past and its always worked well. Im also a fan of not chopping the car up, as alot of people do it because they dont want to spend 5 minutes making something fit properly. Obviously Camerons case is a bit different as his car is pretty much an out and out track car, so the more space you can liberate the better. Plus hes done it the 'proper' chopping way, if that makes sense!

 

There is a fair bit of room even if you want to lower the radiator for throttle bodies and not chop all the front panel off, ive got a few pictures in my project thread.

[Dutch205er 0]

Since i did mine last weekend, at forehand a little confused even after reading different sites about this issue, i made some pics along the cutting.

 

 

 

 

 

 

]

 

 

The fanhousing (fancowling?) feels still strong as original.

[Dutch205er 0]

Have to split it in two posts

 

 

 

 

 

[de Noir 0]

further I'd like to add:

 

shortened radiator springs

 

spring clips (made of cut-out fan cowl plastic)

 

combined detail using std radiator rubber bushings

 

and finished article

[Will Eastman 6]

Iv taken a fair amount out of my fan cowling and the rad is sitting about 1cm away so i'm pretty happy with that, only the bonnet takes a fair bit of closing. Not sure why as when looking down the bonnet catch hole there isn't any obstruction down there from the rad. Is there any way of helping the bonnet closing??