Oscar of Markoz

I bought some alloy bends, silicone hose bends and t-bolt clamps from Aeroflow to make the Intercooler Piping. Some careful measureing and cutting, some tig welding and here is the end result. 
Here is the video of it
https://youtu.be/4IV5Vhu8TMo

I bought some alloy bends, silicone hose bends and t-bolt clamps from Aeroflow to make the Intercooler Piping. Some careful measureing and cutting, some tig welding and here is the end result. 
Here is the video of it
https://youtu.be/4IV5Vhu8TMo

The cortina top mounts (standard) are like that also. They are welded to the top of the radiator and then claw over and get bolted down. I didn't want any mounts to be seen in that radiator support area at all so I went with the different route.
Leo sadly is flat chat with school, even filming he was only able to help me for a small while. I will get him back in there soon though. He has a model car build of his own that he'll be doing soon.
 

The cortina top mounts (standard) are like that also. They are welded to the top of the radiator and then claw over and get bolted down. I didn't want any mounts to be seen in that radiator support area at all so I went with the different route.
Leo sadly is flat chat with school, even filming he was only able to help me for a small while. I will get him back in there soon though. He has a model car build of his own that he'll be doing soon.
 

"On this episode of Australian Cortina ...."
Bought a new alloy radiator, its a VR VS Commodore unit. Just removed the brackets and plates for the standard commodore thermos. Welded on some brackets to mount it up onto the end tanks.
Also cut out the standard cortina radiator mounting area at the bottom towards the front apron lip and made a new one which sits the new radiator further down. Made some pedestal mounts for the radiator dowels and it works like a champ.
Here is a video showing the whole process

"On this episode of Australian Cortina ...."
Bought a new alloy radiator, its a VR VS Commodore unit. Just removed the brackets and plates for the standard commodore thermos. Welded on some brackets to mount it up onto the end tanks.
Also cut out the standard cortina radiator mounting area at the bottom towards the front apron lip and made a new one which sits the new radiator further down. Made some pedestal mounts for the radiator dowels and it works like a champ.
Here is a video showing the whole process

"On todays episode of Australian Cortina ..."
Did some modifying of the Throttle Body. It had these 2 pipes coming out of it which were for vacuum signal and sucking engine fumes from the rocker cover to the throttle body. 
I deleted them and also needed to fatten up the inlet area as the silicone hose reducer was alittle loose for my liking. Plus the T-bolt clamp was wider than the standard lip area of the throttle body.
I ended up buying a small peice of 2mm thick alloy tube, sliced it in half cause the diameter was too small. Added 2 small filler peices and welded it onto the throttle body. 
I added a bead of weld to the end of it so it stops the chances of the hose coming off 
under boost. 




Next up, cooler piping and mounting the radiator

"On todays episode of Australian Cortina ..."
Did some modifying of the Throttle Body. It had these 2 pipes coming out of it which were for vacuum signal and sucking engine fumes from the rocker cover to the throttle body. 
I deleted them and also needed to fatten up the inlet area as the silicone hose reducer was alittle loose for my liking. Plus the T-bolt clamp was wider than the standard lip area of the throttle body.
I ended up buying a small peice of 2mm thick alloy tube, sliced it in half cause the diameter was too small. Added 2 small filler peices and welded it onto the throttle body. 
I added a bead of weld to the end of it so it stops the chances of the hose coming off 
under boost. 




Next up, cooler piping and mounting the radiator

"On todays episode of Australian Cortina ..."
Did some modifying of the Throttle Body. It had these 2 pipes coming out of it which were for vacuum signal and sucking engine fumes from the rocker cover to the throttle body. 
I deleted them and also needed to fatten up the inlet area as the silicone hose reducer was alittle loose for my liking. Plus the T-bolt clamp was wider than the standard lip area of the throttle body.
I ended up buying a small peice of 2mm thick alloy tube, sliced it in half cause the diameter was too small. Added 2 small filler peices and welded it onto the throttle body. 
I added a bead of weld to the end of it so it stops the chances of the hose coming off 
under boost. 




Next up, cooler piping and mounting the radiator

"On todays episode of Australian Cortina ..."
Did some modifying of the Throttle Body. It had these 2 pipes coming out of it which were for vacuum signal and sucking engine fumes from the rocker cover to the throttle body. 
I deleted them and also needed to fatten up the inlet area as the silicone hose reducer was alittle loose for my liking. Plus the T-bolt clamp was wider than the standard lip area of the throttle body.
I ended up buying a small peice of 2mm thick alloy tube, sliced it in half cause the diameter was too small. Added 2 small filler peices and welded it onto the throttle body. 
I added a bead of weld to the end of it so it stops the chances of the hose coming off 
under boost. 




Next up, cooler piping and mounting the radiator

The two bronze ones?

One is breather from rocker cover, should be fine being blocked. Other from memory is for idle speed?

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Nice bit of twisty pipe work there .
looks neat as 

"On todays episode of Australian Cortina ...."
Bought some 3.5" mild steel exhaust pipe and a 90 mandrel bend. The bend wasn't tight enough for what I needed so had to make it all in pie cuts. Tig welded the lot and it turned out pretty good. Smoothed the welds off.
Got some smaller 90 bends for the wastegate pipes out of the turbo manifold and into the dump pipe. The Tial Wastegate came with the V Band clamps which was good. Worked out where to position it and welded the pipes in. 
I'm gonna make a screamer pipe for it later so I can block off the dump pipe outlet and turn the wastegate and the screamer pipe will run down the side and into the trench I made before.







Next up, mount the radiator.

EP8

"On todays episode of Australian Cortina ...."
Bought some 3.5" mild steel exhaust pipe and a 90 mandrel bend. The bend wasn't tight enough for what I needed so had to make it all in pie cuts. Tig welded the lot and it turned out pretty good. Smoothed the welds off.
Got some smaller 90 bends for the wastegate pipes out of the turbo manifold and into the dump pipe. The Tial Wastegate came with the V Band clamps which was good. Worked out where to position it and welded the pipes in. 
I'm gonna make a screamer pipe for it later so I can block off the dump pipe outlet and turn the wastegate and the screamer pipe will run down the side and into the trench I made before.







Next up, mount the radiator.

"On todays episode of Australian Cortina ...."
Bought some 3.5" mild steel exhaust pipe and a 90 mandrel bend. The bend wasn't tight enough for what I needed so had to make it all in pie cuts. Tig welded the lot and it turned out pretty good. Smoothed the welds off.
Got some smaller 90 bends for the wastegate pipes out of the turbo manifold and into the dump pipe. The Tial Wastegate came with the V Band clamps which was good. Worked out where to position it and welded the pipes in. 
I'm gonna make a screamer pipe for it later so I can block off the dump pipe outlet and turn the wastegate and the screamer pipe will run down the side and into the trench I made before.







Next up, mount the radiator.

"On todays episode of Australian Cortina ...."
Bought some 3.5" mild steel exhaust pipe and a 90 mandrel bend. The bend wasn't tight enough for what I needed so had to make it all in pie cuts. Tig welded the lot and it turned out pretty good. Smoothed the welds off.
Got some smaller 90 bends for the wastegate pipes out of the turbo manifold and into the dump pipe. The Tial Wastegate came with the V Band clamps which was good. Worked out where to position it and welded the pipes in. 
I'm gonna make a screamer pipe for it later so I can block off the dump pipe outlet and turn the wastegate and the screamer pipe will run down the side and into the trench I made before.







Next up, mount the radiator.

"On todays episode of Australian Cortina ...."
Bought some 3.5" mild steel exhaust pipe and a 90 mandrel bend. The bend wasn't tight enough for what I needed so had to make it all in pie cuts. Tig welded the lot and it turned out pretty good. Smoothed the welds off.
Got some smaller 90 bends for the wastegate pipes out of the turbo manifold and into the dump pipe. The Tial Wastegate came with the V Band clamps which was good. Worked out where to position it and welded the pipes in. 
I'm gonna make a screamer pipe for it later so I can block off the dump pipe outlet and turn the wastegate and the screamer pipe will run down the side and into the trench I made before.







Next up, mount the radiator.

"On todays episode of Australian Cortina ...."
Bought some 3.5" mild steel exhaust pipe and a 90 mandrel bend. The bend wasn't tight enough for what I needed so had to make it all in pie cuts. Tig welded the lot and it turned out pretty good. Smoothed the welds off.
Got some smaller 90 bends for the wastegate pipes out of the turbo manifold and into the dump pipe. The Tial Wastegate came with the V Band clamps which was good. Worked out where to position it and welded the pipes in. 
I'm gonna make a screamer pipe for it later so I can block off the dump pipe outlet and turn the wastegate and the screamer pipe will run down the side and into the trench I made before.







Next up, mount the radiator.

Awesome build and awesome videos!
I'm a subscriber and definitely worth watching before a lot of the other videos on YouTube.
Keep up the great work!!

The youtube videos are a completely different ball game compared to the photos. Believe me the videos are much better

"On todays episode of Australian Cortina ...."
I bought a CX Racing intercooler a while back and I was at the stage where I could install it. 
I had to cut some metal away from the support braces for the radiator support so that the cooler ends would clear as well as the silicone hoses. 
I made some pedestal brackets to mount the bottom bolt bungs into, so that it sits in place the same as a radiator would. 
I used some 1" grommets so that theres no metal on metal on the pedestals. For the top I bend up some 4mm alloy into Z shapes and used some rivnuts to secure them to the bottom of the radiator support. Its solid as a rock and works a treat. 





Next up, The dump pipe and wastegate pipes.

"On todays episode of Australian Cortina ...."
I bought a CX Racing intercooler a while back and I was at the stage where I could install it. 
I had to cut some metal away from the support braces for the radiator support so that the cooler ends would clear as well as the silicone hoses. 
I made some pedestal brackets to mount the bottom bolt bungs into, so that it sits in place the same as a radiator would. 
I used some 1" grommets so that theres no metal on metal on the pedestals. For the top I bend up some 4mm alloy into Z shapes and used some rivnuts to secure them to the bottom of the radiator support. Its solid as a rock and works a treat. 





Next up, The dump pipe and wastegate pipes.

they are on my list, i'm a subscriber.. will get there soon enough 
 

The youtube videos are a completely different ball game compared to the photos. Believe me the videos are much better