Club 80-90 Forums

I reckon Intercooler .....



Fits in behind the rear light nice and snugly ......



... with the outlet nice and close to the inlet manifold. Good airflow down the C post and with carefully designed extractor ducting ..... yer only man! Just testing the fit using cardboard but will use 1 mm galvanised sheet for all the ducting. Bit of faffing about still to do but thats for next weekend!

where's the inlet though? Mine's set up similar to that but has in and out on the same end. I've got a Motorbike rad fan mounted on the undersude to suck air through

The Inlet will come through the wheel arch which will in effect give extra cooling but protected from stuff that it needs to be protected from! I too will have a motorbike fan in there but maybe on a manual switch for when the air flow isnt there. Still to be decided.

It's cool watching how things like this are worked out. Half the fun it thinking about how its all going to work out and what bits might fit where.

Jed

so will you cut a hole in the bottom of the 'battery tray' ? i was thinking of doing a bernd jager



but now ive had a proper look, and had a play with the intercooler off the golf, i realise that it isnt as simple as sticking it behind the light and sealing the gaps. even bernds one connects to the turbo underneath the van i.e by cutting through the battery tray ( not sure what else to call that bit, it was always the battery tray and spare battery tray in bays and splits). see this picture



which i now realise is looking up from underneath the battery tray. thats the underside of the chassis rail at the top of the image.

in profile, the setup looks like this:


which having written this post is already starting to make sense.

jed the spread wrote:It's cool watching how things like this are worked out. Half the fun it thinking about how its all going to work out and what bits might fit where.

Jed

^ WHS

Air/Air has a lot to recommend it if the airflow issue can be sorted.

Smokeyjon, I'd like to know exactly what model of intercooler you've got, having the in/out on the same side makes this kind of setup much neater.

hotpod wrote:so will you cut a hole in the bottom of the 'battery tray' ?

Yes. There will also be ducting from there to the back of the van. The negative pressure there will hopefully be enough to help with the airflow. If not there is always the fan and motor. Its important though, to seal in the whole rad otherwise you will loose airflow.

Im using an intercooler from a 1995 1Z engined Passat but I thought about getting a rad custom built with in and out beside each other but there isnt a whole lot of room in there so I went for large rad area.

Is this the right way to go? No feckin idea but I cant see why not. Time will tell!

jed the spread wrote:It's cool watching how things like this are worked out. Half the fun it thinking about how its all going to work out and what bits might fit where.

Jed

I like getting close to work stuff out .......

syncropaddy wrote:

jed the spread wrote:It's cool watching how things like this are worked out. Half the fun it thinking about how its all going to work out and what bits might fit where.

Jed

I like getting close to work stuff out .......

Sweet porta potty instal too

Jed

Some of the Americans have good airflow results by venting the D pillar out by the rear lights. Isn't the SAAB chargecooler good for this? http://www.ebay.co.uk/itm/SAAB-900-Clas ... 3f2480111e" onclick="window.open(this.href);return false; as it has inlet/outlet on the same side

lloydy wrote:Some of the Americans have good airflow results by venting the D pillar out by the rear lights. Isn't the SAAB chargecooler good for this? http://www.ebay.co.uk/itm/SAAB-900-Clas ... 3f2480111e" onclick="window.open(this.href);return false; as it has inlet/outlet on the same side

I have one but It doesnt fit the way I want to do the install. I have all the pipework as well (all for sale now)

On an earlier TDI conversion I used a Renault 5 turbo intercooler. It is air to air and has in and outlet on the same side right next to eachother. And it fits flat inside the left tray behind the taillight. I have a spare one if anyone is interested. On my syncro I used a water to air intercooler. There is a german guy in Berlin who custom makes them to fit behind the taillight. Very happy with that setup.

Cheers

Hope you get good results, as it is a much simper set up than a front rad and pipework ect

I have used a Renault 5 Intercooler in the past also.

lloydy wrote:Hope you get good results, as it is a much simper set up than a front rad and pipework ect

Its the main reason for doing it this way. There is little in the difference in efficiency between charge cooling and intercooling but one has the capability to break down. There would be three rads up front - rad, oil cooler and CC rad, five sets of pipes underneath - cooling, heater, power steering, oil cooler and CC pipes and a pump that runs all the time ...... Nah not for me! I wont be fitting a gas temperature gauge either cuz I dont believe they are necessary on such an ordinary engine and I've yet to see an inter/chargecooled car in a showroom with one!

Keep it simple!

Keep it light!