Fitting a Boost Gauge (Ian Kinder)

The gauge is a standard round 50mm diameter type.

The first gauge I bought (Badged as Mocal, made by think Automotive), had a screw on type union on the rear and came with 2m of hard ridged black plastic pipe with one end already terminated to a union suited to terminate to the rear of the gauge.

This also came with a crap white nylon t-piece. The black hose would not fit onto the t-piece due to the black hose being too small. However the 'suppier' said it would expand when heated !!!

I tried boiling water, a hair dryer, a soldering iron and eventually a naked gas flame. Only the gas flame had any result and that was to melt and burn the end.

I Then decided I wasn’t going to bodge something on my pride and joy and took the easy option of visiting a local RS Cosworth Specialist. I then bought a ‘proper’ brass t-piece(didn’t need this in the end), 2m of ‘proper’ flexible rubber turbo hosing (same size and type as the Impreza’s existing waste gate control hose), I also bought another boost gauge (can’t remember the make) from the same chap, with a fitting at the rear to which the rubber hose pushes straight onto.

I now cut of the union from the end of the hard plastic type hose and pushed a length of the rubber hose onto this (only overlapping by an inch) and added a drop of superglue to secure it.

This would then easily connect to the rear of the gauge. (When the first gauge was connected directly to the rigid hose, the hose dictated where the gauge would sit as it was so inflexible).

The rigid hose was pushed through an existing grommet just up from the clutch pedal which comes through into the engine bay hidden behind three brake pipes (located just above the clutch master cylinder). I used the rigid hose for this as the ‘proper’ hose would not probably fit through this grommet.

Once in the engine bay I again fitted a length of rubber hose onto the rigid hose, again using a drop of super glue, and connected it to the manifold on the existing spare manifold port (fitted with a rubber blanking plug) . This port is found on top of the manifold, just beneath the ignition coil on the right hand side front (when standing in front of the engine).

That’s the easy bit done, now the problem of locating the gauge.

I removed the ashtray (I don’t smoke and therefore can live without it), the gauge would just about fit (slightly tight).

I then removed the radio and the console into which the radio, asktray, cigar lighter & clock( held in with four screws, two hidden behind the blanking covers which need gently prising off and two screws covered by the gearstick gaiter.

Once removed, disconnect the wiring plugs for the cigar lighter & clock. I was then able to take the console out of the car into my ‘workshop’ (kitchen floor).

With the gauge held centrally in the slot where the ashtray used to live, I marked the plastic were it was necssary to cut/file to allow a snugger fit of the gauge.

It was quite easy to remove enough plastic from the rear of the console to accomodate the gauge but still allow the ashtray to fit if I take the boost gauge out at a later date.

I then made a blanking plate from a piece of black plastic (a Sega mega drive game box [a video box would have done too). This was carefully cut out with a sharp stanley knife (I’ve still got 10 fingers). This plate becomes two once you’ve cut the two semi-circular pieces out to allow it to mate up to the side of the gauge.

The gauge has two threaded studs on it’s rear. One of these was used to fasten the gauge to the console using an L-shaped piece of steel (I used one of those strips of steel with pre-drilled holes, you get with every car radio you buy).

Once the gauge is bolted in the two blanking pieces were glued in place from the rear using black silicon sealant. This had the benefit of filing in any small imperfections, which would allow the green light from the cigar lighter to shine through.

The gauge was angled slightly to the right prior to gluing.

Once the silicon had cured the gauge light was wired into the cigar lighter bulb feed.

Fitting is a reversal of removal (as they all say). Take care with the console as the plastic is very easily scratched. Ensure the rubber gear lever gaiter is attached to the console before fastening the screws for the console.

I will admit afterwards, the location is not ideal. Line of sight would be better. On top of the dash etc. However I couldn’t think of a tidy way of mounting it anywhere else.

If I find a better place, I’ll move it and put the ash tray back in !!

I hope this helps,

Regards, Ian

 

(The ISDC cannot be held responsible for any modifications that adversely effect the warranty of your car.)