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Have you ever tried mikalor hose clamps ?, those are very tough but im guessing the welding sorted it now.

Really good stuff, glad i could help out somewhat. Forgot to mention that the map sensor does need changing to the delphi 2.2tdci one which is around £60. Honestly, if your ecu is accessible i would post it to save the headache of mapping it yourself if you interested in hdi tuning. I think greg...

The easiest and cheapest way to get to that power level with the supporting mods is actually quite easy and accessible. - get injectors and fuel pump tested otherwise you might limb mode, if they need refurbishing, greg got a guy. - buy the 1752 turbo from xman turbos part number: 7607441752...

I tried the same initially, with modifications to the hangers and the joint. Worked fine, no noise just for looks. Issue is that the T5s flow so much that the back box restricts a lot on the 2.0d platforms. Also if you got a pre facelift you might have the 2.25 inch midpipe which is gonna need a...

Yes i have the delphi 2.2tdci map sensor found on various platforms. Make sure its the 3 pin sensor with 1 screw bolt.

Also recently switched maps to a hdi tuning stage 2 map promising 195 bhp havent been on the dyno yet but feels very strong indeed. Highly recommended for anyone wanting the max out their stock 1749 turbo.

https://www.printpeelstick.co.uk/products/ford-focus-mk2-2-0-tdci-turbo-boost-hose-kit-enhanced-performance This silicon pipe kit works very nice with the gravity performance highflow st225 intercooler.

Anyways, was at dynodaze made 191bhp and 310 ft lb on a custom dyno map. Runs very nice with the popcorn but annoyingly the exhaust now produces a loud choo noise in every gear throughout the rev range :/

Lucky car i suppose, or the facelift is worse.

You must be running some upgraded mounts lol, my clutch and flywheel hate me.

Basically our platform runs a Dual Mass Flywheel (DMF) and you can convert it to a Single Mass Flywheel (SMF), looking into it because my current dmf is engaging poorly and i might get a higher life on the smf…not sure about the performance aspect tho hence why i asked.

Is anyone running a smf conversion or looked into it ?…found a conversion kit and wondered how good it may be.

Would be a custom tune with all the extras, like hardcut limiter n lambda delete. Im in talks with three tuners in the midlands which are: Dynodaze Profile Tuning Midland Remaps Im yet to decide who i will go with. Maybe greg can jump in and let us know about his tuner lol.

Thanks for the reply greg, you cleared things up for me because tuners have been saying i need a bigger intercooler. Clearly you have experimented around and made your s40 a real weapon lol. Do you think these specs are enough to run a stage 2, at around 195bhp ? -gutted cat -2.5 inch mid pipe...

Thank You for the reply Greg. I had a look and for some reason the space between my radiator and crashbar is about 45mm.....the Airtec starts at 60mm.....might be a facelift issue, do you have any other suggestion perhabs ? My current setup is running at 187 bhp & 423nm with a standard st225...

Im looking at an upgrade and was wondering how i can get a bigger intercooler in without modifying my crashbar on a facelift S40.