Clio Mk2 Mirror Intake

[ZFJ Ben]

Last year, for my second year project at college (Studying motorsport engineering) I designed and prototyped a cabin cooling system routed through the mirrors of the car. The design allows for the mirror to still function, but at a fixed angle. A 30mm intake pipe forces outside air into the cabine. ( I had planned on adding an electric fan to aid the air, but havent got around to it.)

Basically this thread is there to show people how to make on of my design and also ask any questions about it.

Obviously the one I produced is a prototype so it can be improved in certain ways and also I dont care if people make loads of my design, but just remember that it was ME who made it first.

Ben Andrews (ZFJBen)

 

[ZFJ Ben]

Standard mirror - 700g

Modified intake mirror - 480g

 

[ZFJ Ben]

Cars that use a simular system;
Audi quatrro s1

Random BMW race car spotted at Autosport

 

[ZFJ Ben]

If anyone would like the full step by step process i can put together a document with all the pictures and instructions :smile:

 

[billinjah]

I like that idea! Any more pics?

 

[Louis]

I like the idea of having it in the wing mirror, pretty neat. The only problem is that you're only flowing air that's the same temperature as outside. If it's hot, you're flowing hot air. I get that a lot of time it's just the feed of air that you want though.

Could have done something really neat with the actual black trim area. I like it though.

 

[ZFJ Ben]

I like that idea! Any more pics?

 

[ZFJ Ben]

Step 1 - Mirror removal

-Unblot the mirror by removing a plastic trim on the inside side of the door. For all sport models and some non-sport models there will be wiring for the mirrors motor, heater and outside temp sensor (only on the passenger mirror). Unplug the connector. Next there is three small 8mm bolts covered by rubber grommets. Unbolt the mirror, remembering to be careful that the mirror doesnt drop to the floor (Unwind the window to hold the mirror whilst unbolting).

 

[ZFJ Ben]

Step 2 - Mirror strip down

-Carfully remove the colour matched outer cover. Try to use trim removal tools or flat head screw drivers. Theres about 5 clips that hold the cover on, its very hard not to break any clips, but try to break as little as many.
-To remove the mirror glass push down on one side so it lifts the other up, get a small flat head and prise off. It shouldnt be too tight on, however there is two connectors connected to the glass so remove them before taking the glass fully off.

-To remove the motor and main electrics, there is 3 gold philips screws. Unscrew then the motor will be lose. On the back of the motor, the wiring is connected by one plug with 3 wires going into it. This can be tricky to remove but if you take the back cover of the motor off, it'll just unplug. The motor can now be put to one side. You wont need it agian.....

- To remove the final bit of wiring the main connector (That plugs into the car) need to be unscrewed then the wires can be pulled through. It will now leave you with an empty mirror shell that still hindges.

 

[ZFJ Ben]

Step 3 - Splitting the shell into to parts
-For the piping to be correctly routed through the mirror, the hinge needs to be removed. Metal hinge is very stubborn to remove so there will be multiple ways of doing this. But i used a combination of hacksaw and dremel.

 

[ZFJ Ben]

Step 4 - Making room for the piping
- The largest size of piping I have been able to use in the space is 32mm revotec single layer neoprene ducting. I bought mine from Merlin Motorsport, as they are close to me and I could get specific sizes. https://www.merlinmotorsport.co.uk/p/revotec-black-single-layer-neoprene-ducting-per-metre-rev-blk
- Firstly the door mount part, needed to be modified. The orignial hole where the hinge was, needs to be enlarged. The original hole was 25mm in diameter. This needs to be 40mm in daimeter, but offseted towards the car side of the door mount.

- The mirror housing part will also need to be modified. If you look at the back of the part the dome shape goes flat in a bullet shape. On this flat there is a hole and other strengthening parts. From the outside edge of the falt, go in 5mm, from the top edge go in 10mm and the bottom edge 15mm. Remove the plastic in this area, going all the way up to the inside edge where the inside of the mirror meets two holes, like in the picture below.

- Test fit with the pipe to make sure that it all fits in the space you have just made.