ZD30 Catch Can installation & inter cooler replacement

Vehicle modifications/repairs/rebuilds
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Tinus lotz
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Re: ZD30 intercooler replacement

Post by Tinus lotz » 16 Apr 2013 15:27

:thumbup: :thumbup: :thumbup:

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Re: ZD30 intercooler replacement

Post by Stefan » 17 Apr 2013 13:10

Gisteraand gou die catch-can geinstalleer met die nuwe boutjies.

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Image

Nou nog net die pype.

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Re: ZD30 intercooler replacement

Post by Tinus lotz » 17 Apr 2013 14:32

mooi man het jy al nuwe brackets gemaak ?

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Re: ZD30 intercooler replacement

Post by Stefan » 17 Apr 2013 15:05

Nee, gaan die naweek daai ding doen.

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Re: ZD30 intercooler replacement

Post by Stefan » 17 Apr 2013 20:55

And the fitting of the pipes completes the installation of the catch-can.

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Re: ZD30 Catch Can installation & inter cooler replacement

Post by Stefan » 22 Apr 2013 16:21

Ok, so I managed to get some more work done on Saturday. Not as much as was planned, but then that is the case more often than not.
The first step to making the brackets is to position the intercooler, as per Driko’s photos, as far back as possible and centred with the scoop.
In order to move the intercooler back a piece of the supplied piping needs to be trimmed back, measured as in the picture, leaving a little gap that could be trimmed back further if required.
Image

Having determined the piece to be cut, I tightened the clamp around the hose to provide a guide for a nice clean cut.

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For the front-right hand side bracket a 90⁰ bend was required. As I don’t own a vice, this was the result.

Image

I proceeded to drill an 8mm hole in the bracket and then fixed it in place to get a location where it would join the flat bar running between this mounting point and the one behind it.

Image

Next came the welding.

Image

Those of you with a keen eye for detail will notice the famous ‘Fisherman’ technique employed in this photograph to make the weld appear a lot better than what it actually is.

When I managed to get good penetration on all 4 welds an offered it in position, it turned out that the flat bar should have been on the inter-cooler side of the 90⁰ bend (as clearly shown in Driko’s pictures). :redface:

For the next right-hand side bracket, I'm going to require a much tighter 90⁰ bend, so I'm either going to have to cut the steel and weld a 90⁰ angle (least preferred option), get some kind of angle-iron with longish sides, or employ some kind of jig to bend the flatbar (There is the start of an idea in my head that involves a hydraulic jack. :surprised:

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Re: ZD30 Catch Can installation & inter cooler replacement

Post by davidvdm » 22 Apr 2013 16:55

Cut the flat bar half way through on one of it's surfaces so you have a weak point where you can bend it, then after the bend is made, just lay a weld in the gap that is left where the cut has been stretched open. You can even grind it all flat and nice looking afterwards.

If you go deep enough, you can just about bend that thing by hand and then weld it back up, or use some place to wedge the end into and do the bend, even my tow bar and rock sliders have come in handy for times like this (before I had my vice set up in my new house).
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Re: ZD30 Catch Can installation & inter cooler replacement

Post by Dave Faddel » 29 Apr 2013 15:38

Hi Stefan,
What were the cost's of the various parts and can they be bought seperatly?

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Re: ZD30 Catch Can installation & inter cooler replacement

Post by Stefan » 30 Apr 2013 07:49

Hi Dave,

I didn't find out, I just got the kit from Driko.

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Re: ZD30 Catch Can installation & inter cooler replacement

Post by Tinus lotz » 30 Apr 2013 12:08

looks nice man!!! :thumbup: :thumbup: :thumbup:

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