Twin intercoolers

[nathan_b]

So, apparently the 240hp TT has dual side mount intercoolers.

Which has me thinking, anyone ever mount two intercoolers NOT parallel on a 1.6td?

I am going to be intercooling my frankenmotor soon and will be swapping out my k14 for a k24, but the problem I have been having is just too much boost. If I rotate my boost pin (which is ground SLIGHTLY), and put in any kind of max fuel setting that is reasonable (No smoke anywhere btw, none) boost goes bam, instantly as high as I want it, if I weren't careful to keep the aaz turbo below 19psi, it could spike to wayyy to high, probably 30+psi. But the wastegate is stuck shut. But this has me thinking, why not use the excess boost to counter the potential boost drop that 8ft of tubing and 2 med sized intercoolers would give?

By egts are like 1100f MAX flooring it up a long grade at 70mph. and 550f cruising. after a nice 0-60 run egts are under 800f. So I have lots of room to play with.

Caddy has 2.25 straight dp, 1.6td pump/injectors stock, but tuned. I can put the star wheel so it doesn't even touch the spring and put the "smoke" screw all the way in and still no smoke on the steepest setting, so I am waiting to see what this beast could devour with a bigger turbo and intercooling.

Let me know hwat you guys think, not trying to change the world, jjust have a lot of intetrcoolers to play with for the moment and keep thinking of things to try. I also have a huge volvo intercooler, but ti has plastic end caps.  Anyways, back to the topic at hand... Dual intercoolers...

[Digital K]

they do this on a TT because theres nowhere else to put a bigger intercooler.

[Alcaid]

...But the wastegate is stuck shut...

This is what you really should use your energy on solving...

[nathan_b]

Except the tune is not in a permanent state, so a stuck wastegate is great for a mild tune. But I am searching for more power.

I know everyone is stuck on saying a single fmic is best, or TT just did this because no space, which is BS because mk5s use a fmic on the 2.0t and make less power with a far superior engine. In fact, a common mod on mk5 2.0ts is to add an additional fmic to the stock unit.

So I am just really skeptical that there is ANY conclusive tests to disprove my theory, other than "that's not just the way it's done." Which is BS because to the rest of the vw world, making diesels fast is "just not the way its done."

[rodpaslow]

MY .02$, usually you need much more connections be it rubber/silicone connectors and steel or aluminum between connectors.  The steel or aluminum is usually thin wall tubing.  It may be possible to have the same length of tubing for a dual mount, but I think in most cases there is more actual length of tubing and connectors to setup something that may have come factory from Vw.  This does make some difference.  I have a air to water intercooler and my tank is in the hatch at the back of the car.  In +5-10°C temperature we are currently having, the tank doesn't even get warm and I'm sure its due to the length of water tubing I have to run to the back of the car.  May be...

[8v-of-fury]

A really big pan (radiator size) Air-to-Water intercooler will ultimately be the best cooling you could provide. Or maybe TWO AWIC

[R.O.R-2.0]

Except the tune is not in a permanent state, so a stuck wastegate is great for a mild tune. But I am searching for more power.

I know everyone is stuck on saying a single fmic is best, or TT just did this because no space, which is BS because mk5s use a fmic on the 2.0t and make less power with a far superior engine. In fact, a common mod on mk5 2.0ts is to add an additional fmic to the stock unit.

So I am just really skeptical that there is ANY conclusive tests to disprove my theory, other than "that's not just the way it's done." Which is BS because to the rest of the vw world, making diesels fast is "just not the way its done."

no, a stuck wastegate is horrible for a mild tune. i would want loads of fuel, like enough fuel to be burnt by all that boost. over boosting your engine is counter productive..

and i would also rather have 1 big intercooler, or 2 turbos, and an intercooler between each stage. 

[bugnut]

A stuck closed wastegate is bad for any type of tune.  You are creating a bottle neck at the upper rpms when that is closed.  Get that thing working and I bet you find more power.  Check your drivepressure, I bet it is through the roof on the top end.  Have it set to open at 15psi or12 psi and feel how much more power you got.

  I have done test with this at the track. I wanted more boost so I cranked it up and ran slower.  I made all the exhaust run through the turbo.  Sure I had more boost but power was down.  The exhaust could not get out fast enough.  Dropped the pressure back down and sure enough I went faster. 

 From the looks of your egt you have a lot of room to grow with your fueling.  Add an intercooler, thats even better.