Well time for a bit of an update, been busy on the car every month doing little bits here and there slowly progressing, heres what ive done since.
Relocated Battery to boot with 0 guage audio power cable, ran the cable in the cabin for safety and made sure nothing will rub through didnt take many pics as i got a new cell phone during the process:
got my new wheels finally, car just needs a nice drop on coilovers in future
Then with the battery out the way i was finally able to start getting the intercooler planned and fitted, i wanted to try minimize the cutting on the bumper so i mounted it such a way that i would only have to trim the sides sligtly and the bottom would of the bumper would still be there to bolt on for stability:
with the intercooler all clearing and planned the bumper could now be removed:
mocked up the number plate and indicators to avoid any traffic fines.
hole cut where battery used to be, must still spray the area:
some new radiator brackets i made now that the pesky oem boost pipe was out the way:
Side mount intercooler removed and original hole ready for boost pipe, no need to cut further:
bottom of intercooler secure after having additional bungs welded on:
all prep work done and now it was time to start TIG welding

this is the hot side 50mm boost pipe out of 304 stainless steel:
now time for the 63mm cold side, took me hours to get the shape right and the bends cut right for there to be no gap between the pieces as to fuse weld them together it the gaps must be almost air tight or else you just burn holes and then youll have to make use of ugly filler rod
and heres the almost finished product, still need to get an adaptor machined up to fit my new dump valve and some touch ups to be done, must still have bumper resprayed to fit it back, but so far im quite happy.
no boost leaks as of yet and the T-clamps are doing a great job keeping the pipes in place, even when my wonky boost controller was letting out 1.3bar the boost pipes did not budge and my intake is cool to the touch after driving the car like a maniac, when with the side mount intercooler the intake used to feel pretty hot after a hard drive. so its definately doing its job
