Re-enforcing the rebar and making a shroud or ducting to control the air flow into the FMIC.

OK let's start with the rebar modification. At first we were thinking of making a totally new rebar but after analyzing the situation (time constraints) and talking with a few individuals on the A4 forums we decided to keep the original rebar and modify it to fit our purposes. It would have been nice to use the digital milling machine to do the work but alas it works on 550V and the shop is not yet equipped with it. So we decided instead of sending it out to another shop that we would handle it our selves by more traditional means (time constraints again).... Yes we used cutting tools to do the job!


Here's what it looked at after the initial cutting. There was a lot of material removed.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Symo-Sport-FMIC-Rebarmod-July17.jpg">


Another view of the rebar.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Symo-Sport-FMIC-Rebarmod-Jul-1.jpg">


Here's most of the removed section from the rebar. The black aluminium brackets were used to hold my Setrab oil cooler in place.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Symo-Sport-FMIC-Rebarmod-Jul-2.jpg">


3/4 view of the rebar with the FMIC being test fitted.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Symo-Sport-FMIC-Rebarmod-Jul-3.jpg">


Full front view.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Symo-Sport-FMIC-Rebarmod-Jul-4.jpg">


We wanted to have the brackets done by a CNC machine but again to design it with a CAD program and them have a shop machine it was to time consuming (for me) so we made one ourselves. It's welded to the rebar on the right side of the FMIC.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Symo-Sport-FMIC-Rebarmod-July18.jpg">


These are the treaded attach point welded to the side of the FMIC.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Symo-Sport-FMIC-Rebarmod-Jul-5.jpg">


For the left side things were trickier because the outlet from the I/C comes out at the top where the bracket would be located. So we decided on a top mounted bracket that is welded to the top end tank and then bolted to the rebar.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Symo-Sport-FMIC-Rebarmod-Jul-6.jpg">


Another angle of the top mounted bracket.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Symo-Sport-FMIC-Rebarmod-Jul-7.jpg">


We wanted to re-enforce the rebar and we also wanted to control the airflow to and into the FMIC. So we thought up of this. We used an aluminium sheet cut down to the proper size that would be welded to the rebar to strength it and also act as a duct or air shroud to keep the air from flowing outwards and into the I/C. We also finished off the endings in a nice curved finish.


First the curved endings were installed.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Symo-Sport-FMIC-Rebarmod-Jul-8.jpg">


Close up of the curve ending.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Symo-Sport-FMIC-Rebarmod-Jul-9.jpg">


The other side.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Symo-Sport-FMIC-Rebarmod-Jul-10.jpg">


The left side welded on.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Symo-Sport-FMIC-Rebarmod-Jul-12.jpg">


The right side welded on you can also see the bracket.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Symo-Sport-FMIC-Rebarmod-Jul-13.jpg">


Finally the whole rebar with its re-enforcement/duct system. This is the front view and you cannot see how the rear portion is going to sit real close to the FMIC to block the air from escaping.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Symo-Sport-FMIC-Rebarmod-Jul-14.jpg">


Now we test fitted the newly modified rebar by putting on the body kit. As you can see in this picture (top/side view), you see the top end tank, the top bracket and the newly re-enforced rebar with its duct just sitting near the FMIC's core. There is barely a 1/16 on an inch to spare. The air is going to go through the FMIC, trust me.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Symo-Sport-FMIC-Rebarmod-Jul-15.jpg">


Front view with the body kit.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Symo-Sport-FMIC-Rebarmod-Jul-16.jpg">


Close up. Both sides and the bottom portion will be closed up by more aluminium sheeting to duct the entire front of the FMIC.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Symo-Sport-FMIC-Rebarmod-Jul-17.jpg">


Looking up towards the top tank. The core sits very close to the Caractere mesh grill, I'd say less then a quarter inch. This will make it easy to duct the sides and the bottom portion to make it a fully closed in air duct system.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Symo-Sport-FMIC-Rebarmod-Jul-18.jpg">


Here's a picture without the body kit showing the top portion of the core with the duct/re-enforcement of the rebar.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-Symo-Sport-FMIC-Rebarmod-Jul-19.jpg">

I'm sure it wasn't for the price reasons because this couldn't have cost you much less.

Already invested in this project and it's still not finished. I hope it pays dividends when finished.