Very good!
Right! An update from me... No photos at the moment, but I will get some up asap. Sorry for the wordage, but I hope it's interesting reading:
I was driving the car fairly spiritedly along some of my local back roads and loving it - it's still taking me some time to gain confidence with the car and explore its performance and handling properly. After my earlier "off" I am trying to treat the car with a bit more respect, but also trying to see what it is capable of without scaring myself silly! Anyway, one time I accelerated there was a pop and psshhttt.... noise! Followed by no/little boost but the sound of escaping air. Oh well! I'd obviously blown an intercooler or boost pipe or something! I took a look but couldn't see anything, so proceeded back home.
Good excuse to fit the slimline fans and FMIC I had lying around that I'd bought from
@la21t, but I did have a proper look to see if I could see anything amiss! Nope, but I did see a small pool of coolant under the car, but it wasn't losing enough to be a major concern.
I tried checking the intercoolers and changed a pipe but that didn't fix the issue, so decided to bite the bullet and fit the FMIC!
I fitted the slimline Pacet fans - they went on easily enough. One had the original connector on it, but the other didn't have anything on it, so I soldered and heat-shrinked it on! It was at that point that I noticed that there was a fan earth that was missing, so rectified that, to discover that it made both fans spin faster, and one faster than the other - I am not sure if that's correct - not quite sure how they should come on? Anyway, they seem to be independently controlled, and the relays don't engage/disengage at exactly the same time. I also noticed that while idling, the fans only come on for a second or two then go off almost immediately. I also found that before the additional earth was fixed, they would only work at all if they were both wired in - one was obviously earthing "through" the other.
So that being done, I went about fitting the FMIC. I had to buy a load of silicone hoses, reducers, bends, joiners, etc... I did the best I could but realise that it's a bit sub-optimal as the angles and lengths are a bit difficult to get exactly right, but I decided just to buy what I could to get it working and then optimise it later.
It was as I was dismantling everything and trial fitting things that I discovered that the original flexi-boost hose that goes to the intake plenum was the part that had failed. It had a big gash in it where it had split under one of the plastic rings! Luckily I have a spare and used it to fit the FMIC as I found it would juuust push on the outlet from the FMIC.
I also cheated and bought a long flexi hose for the air filter and bought a cheap cone-type filter. Easiest way to just get going.
Anyway, I fitted everything up and got it plumbed in. I don't have a proper breather yet - just put the pipe next to the air filter. Want to fix that later. I have a spare brand-new oil catch tank so will be using that at some point!
Then came the joy of fitting the bumper! My bumper is a bit knackered anyway so I didn't feel too bad about chopping it a bit - I had to "clearance" it a bit around the bottom edge and the fog light housings but I did kind of get it on. It entailed a lot of faffing around with the mounting brackets (I got some metal brackets from an earlier car - they seem much better than the Ph3 plastic jobbies!
I even got my daughter to lean against the bumper to push it home. Thank you to my kindly 9-year old girl

Time to go for a drive! And yes, I have told my insurance company about the mods! Interestingly, they didn't ask for any more money at all. And, they only charged me an extra £10 to double my annual mileage allowance from 3000 to 6000.
Took the kids with me as I needed to take them somewhere. The car really did feel more responsive and definitely faster. I also like the noises! There's more turbo whistle, and also there are some nice noises when I lift off the throttle. There's no dump valve fitted and in retrospect I think the VAG one I had fitted before wasn't working properly - probably too hard a spring, but I digress.
We'd gone about 10 miles and I was just accelerating up a long hill and there was another psshhtttt noise followed by total lack of boost! Ooops! Obviously blown a hose off! That was interesting. I could hear the turbo whistling away but I didn't want to push the car for fear of overspeeding the turbo, since the wastegate would never have opened. Is that a risk? I don't know. So I carefully got to the top of the hill, and coasted down the next. I was able to get to a Halfords pretty easily, so I popped in and bought some spanners after seeing which clamp had blown. I didn't have any tools with me at the time!
I fixed it back on and continued on my way. Lovely!
Because I was in a hurry to get going, I didn't bother fitting the nose cone and my left-indicator wasn't secured properly (the spring retainer is broken), and it fell out on the motorway! Luckily still attached by the wiring, so I didn't lose it. And the bumper wasn't well attached at all, so it dropped! I need to fit captive nuts onto the metal brackets as they were threaded, but I don't think the thread is good enough/deep enough, so I think the bolts were pulling through.
While I was at the job, I saw that the hoses around the right-hand side of the engine were the cause of the coolant leak(s)! They hadn't been done up tightly enough, so I re-seated them, which seems to have cured the leaks.
I also found that the metal retaining clip thing for the plug for the IACV was missing, so I fitted one I had previously dropped on the floor while fixing the GTT and didn't think I needed(!) as it was from a broken anti-perc fan connector. I also noticed that the plug for the coolant temperature sensor was half broken, so I ordered a couple of new AMP plugs from our friend Scoff at
http://www.efi-parts.co.uk/
I can see me getting him to fit an Adaptronic ECU at some point - can't wait!
Next to-do:
- Remove the bumper - cut out a bit more of the fog light housings and generally get it to fit a bit better
- Buy and fit some mesh to cover the cut-outs for the fogs. Who needs front fogs anyway??
- Once I am happy with the fit of the bumper, modify and fit the new bumper as shortly to be supplied by Oliver (he is spraying it for me)
- Fit the new coolant sensor plug
- Fit the oil catch tank and plumb in the return from it to the air intake just aft of the air filter
- Optimise the boost piping and tidy it up a bit. Fix the air filter to something - anything! It's just floating right now
- Fit the new turbo I have on order from @DaveL485 - can't wait, but I will need a new downpipe - there's a place fairly local to me that will do it, I think
- I want to fit one of these (or similar) as I find the Scorpion exhaust too quiet sometimes, but want the quietness for cruising: http://www.ebay.co.uk/itm/2-5-Elect...787?pt=LH_DefaultDomain_3&hash=item259aa1531b - should I still have one silencer in line before it, or should I go for the no silencer at all effect??
- Fix the central locking for the boot
- Get the front driver's wing straightened at the bottom and fitted properly
- Spray driver's inner wing red inside the engine bay
- Fit the driver's wheelarch guard. Have new clips ready
- Put the steering wheel on straight! It's not been straight since the tracking was done
- Fix some of the interior rattles
- Drive the bloomin' thing!