Hey guys,

Just starting a thread on the new mods I did, and some of the installation dramas I had.

First of all, I previously just had a custom tuned edit.. and before long, I needed more

Anyway, I decided to do injectors, intercooler, fuel pump, magic 4inch cat, and mal wood option 2 clutch.

Clutch was the first to go in, and after some initial shuddering and some worrying, I decided to re-bleed the clutch (following advice from ben and mal). Originally the clutch was fitted here in canberra, not by mal wood automotive, and gear selection was hard, and bordering on down right impossible to hit first or reverse! Anyway, I had transmaxz put in, and later my mate re-bled the clutch.. Not only did the insane shudder from take off disappear, but it is now perfect to select any gear... top choice of clutch for anyone in the market! Highly recommended..

Next to go in was the IC. Provided from ASE. Quality of intercooler looks great. Installation was a little harder then just "bolt" straight in. Luckily I had the services of a very good mate, who is very good at his job! After 5 hours of mucking around, (re-welding, re-positioning certain brackets, and some grinding of front bar) it was finally installed, and I must say it looks great. I have some final pics of it to come, and have some installation pics... although forgive me, beer was at hand, so I forgot to take quality pics!

Cat was no dramas, a local exhaust place here in canberra did the work at a good price!

From the experience of the IC installation, I would not recommend it to anyone who is not mechanically minded or has at least some idea!

Injectors were the next installation... these went in rather easily... so not much to mention here! And the walbro fuel pump was the same.

Simon from extreme ford tuning provided the tune, and it is due on the dyno tomorrow, but after a quick drive on the 95ron map (the gay tune - as simon put it) I was very impressed!! If that's the gay tune, I can't wait to give tune 3 a belt tomorrow!! Cheers Simon!!

I will post up more details when I have further pics, and when I know the results of the dyno session, but from seat of pants feel, I can tell I'm gonna love tune number 3

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Pic one is of the left hand side of front bar, no grinding of this side was needed.

Pic two is of the right hand side, and as you can see some of the bar was grinded. Both left and right side are symmetrical, so you get a rough idea of how much was ground by looking at how close it is ground to the hole.

Next two pics are just comparison images of the two coolers. More pics to come, and final results!! But so far I am one happy man!

Especially considering I've been driving around in a stocker for the past 6 to 8 weeks!! Guess I better start saving for the T56 conversion now!!

what is mal woods option 2 and how much??

keen to hear your results after the dyno run

Thanks for write up Jimmy.

So there's a bit to grind off the bar hey.

What did you have to weld? If you have to get a welder out that's hardly a DIY intercooler.

ye im sure ud be rapt with the car hey

and simon sure does know his stuff on theres cars

Mal Wood option 2 is the 10.5 inch sprung cushioned ceremetallic clutch, which uses the original fly wheel. Good for around 330rwkw. Cost is $975. I had it fitted here in canberra for $300.

The bits that needed welding were the brackets. Although they didn't require welding, my mate rewelded two of the brackets together to extend them, so that he could fit it the way he wanted. The original brackets would have needed more grinding, and it also cramped the intercooler hose a little too much for his liking.

He probably only ground off around 3mm thick, over a distance of 7cm. The grinding wasn't the problem, it was figuring out where the brackets would be best suited other then that, its a great looking cooler, and I'll see shortly how the performance side goes!!

cost me $183 to have the car dyno'd... that's almost as much as a friggin custom tune!!! And they're printer doesn't even work!! So I have to pick up the graphs later... I don't think I'll go back there!!

But now to the real issue... it appears that the car was breaking down under load, and is more then likely a spark plug issue. I haven't yet had a chance to speak with Simon, as he's probably still asleep! So I won't bother him yet.

Also, it was evident that there was some valve spring issue, however this was well and truly after peak power was made. Car made under 260rwkw on tune number 3. Tune 2 and 3 made 232rwkw each.

The 260rwkw feels a lot stronger and better then my previous 250rwkw, and this is because boost comes in a lot earlier.

Anyways, I will have to speak with Simon and find out what he'd like me to do. Tune 3 breaks traction in 1st and 2nd However, I don't think its at full potential if the plugs are breaking down under load!!

And so the journey continues...

Hey mate, regap the plugs and you can now send me the box so I can finish it off, Once you do plugs and springs you will get over 300 rwkw's no probs, Tune 1 was an 95 ron tune , tune 2 was low end 98 and tune 3 was your base 98, once ive seen the graphs of the afr's and heard what the dyno operator has had to say I can finish it off.

It's always tough to tune over distance but Simon is good at it, so pretty soon you'll in the 300's.

Cheers Simon,

Big wraps to you mate... its a great testimony to you, to be on the other side of the country and have the tune perfect (bar my plugs). I dont even think your tune needs much of a touch up to be honest!! But I will email you the graphs, and I'll re-do the plugs on thursday, and then we can take it from there.

AFRs are pretty much spoton as I mentioned to you over the phone. Glen (dyno operator) also included another table of information with rpm, km/h, Nm, Kw, MAP pressure, etc etc.. so that might make it easier for you, I dunno!

DAMN those power curves look smooth as mate! Can't wait to sort the plug issue out. I shouldn't need a dyno run after plugs??? Not at $183 a pop... I'll go elsewhere I think. Or maybe I'll just do the run after you've done your touch ups... not that I think there is much to touch up!!

I'm very happy with the low down power... showed a monaro what for today

Good luck with it Jimmy - at least the $183 bought you a good dyno and an even better operator - shame his boss wont let him go down the Edit path...wasted talent. Not wishing to come across as a smart-arse but this is the reason why I preferred the costs and hassles with a custom tune where everyting is sorted there and then which removes the guess work and frustration versus at least 3 separate dyno pulls coming to near $500 and closr to the cost of a custom tune with as many dyno pulls as are needed to get the results.

Dingah