It's nearly two years ago that I decided to do what I've dreamed of since I got my first cherry red Le Mans with Gti6 engine; supercharge it. Got a golden Gti body three years ago to fit my Citroen RFS engine in, much better looking and a lot less rust! So, much saving and scrounging parts later I ended up with all the parts needed. Many thanks to Rich W and a few of the forum members here! I wanted to keep both power steering and AC so I got me two 106 epas pumps and a same side intercooler and spend many weekends figuring out how to put it all together.
First week of March 2020 (a week before Corona hit here in the Netherlands) I started work with my trusty mechanic.
Two weeks later, she runs! Build pics below.
Cutting out bits of bumper to make room for the intercooler
Trial fit of the first intercooler, this one was way too big and I coudn't fit my outer bumper over it so I went with a smaller one later on. Also you can see the first (open) version of the fan shroud here, I went with a closed version later as this builds up more pressure at the front of the radiator resulting in better cooling.
Horizontally mounted the 106 epas pump as low as possible
Some ugly but functional welding, resused the ABS bracket screw
Somewhat oversized intercooler, bigger is better and who knows what the future brings
Bends still fit!
Yes, my fan shroud is ugly but it works
Mounted the Rotrex cooler sideways, didn't use the extension at the top
Had the 2.5" exhaust fitted first. Unfortunately extremely loud and boomy
Taken things apart
Most pricy part ever gets to go on first
Polished the inlet manifold a bit
Air filter has already done a few miles as I used it in my homemade intake so could access the epas pump location a bit easier
Wire stuff, so much fun (go to do that twice as I made a mistake somewhere)
Pipes looking very tidy!
Added an aluminium strip at the top of the radiator as most cool air seemed to slip out that way instead of going though the radiator
Put some pipes in the bends, difference is huge. Both visually as in throttle response.
At 84.5% of the first and longest and slowest 100km of all times
Checking if nothing is leaking while there's some daylight left
Mounted the oilcooler for the second time, first time the lines got in the way of the bumper; rookie mistake
It barely fits, as do most of the extra parts ;-)