Building AAZ motor; meet Harley

[GEE-BEE]

Send me your address and the o.d. of the hose clamps, I will send you some lined s/s type free...

I hate to see that junk being used...

GB

[CrazyAndy]

Okay, I'll PM you and we can work something out.  Sorry if I don't know of other types of clamps; AutoZone only gets so fancy.

 This weekend I finally got the mounting for the oil cooler finalized; paired with some pre-drilled bracket stock and an oil filter that is short enough to be used with my oil cooler take-off (I'll get a little longer one after first warm-up), the main components of the oil cooler are mounted.  The plus is that the cooler can fit behind the radiator with it having to be canted back only about 3-4 degrees!  The only other things I have to do on that part of the job is find out which hose is the supply hose so I can make it feed the cooler end opposite the temperature sensor so the fan relay sees the oil temps post-cooler; that way the cooler fan isn't always running from the hot pre-cooled oil.
  I also did some test mounting of the AWIC core, and I can continue with the plan for mounting it on it's side.  I had to move the core fan up so that it can fit behind the radiator and not have to slant the radiator more, but it works.  After fiddling with the potential hose routing (you can see in the 7th photo I pondered passing it over the top of the oil cooler), I decided to pass both hoses below the oil cooler since there's enough room as the 5th pic shows.  I thought about where I could mount the AWIC circulation pump, and I was thinking in the fender well between the sheet metal and frame horn like in the last pic would be a nice, low point in the system to put it at.  I just need to make sure the pump feeds from the cold side of the AWIC radiator to the core inlet, so that way the pump stays as cool as it can be.
  I finally banged out how I'd like the AWIC core to mount in the air box area: Turned about 30 deg. clockwise with a downward slope equal to that of the hood.  I just need to make the compressor-to-core hose configuration a 2"-2" 90 deg. band, and a 2"-2.5" 45 deg. bend, and then make the core outlet a 2.5"2" 135 deg. bend; it's all 2" piping and smooth 90 deg. bends from there.
  And through it all, I still haven't remembered to buy new rad hoses and modify my rear TB cover trans mount; derp!

[vanbcguy]

Nice looking intercooler!

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[CrazyAndy]

Thanks; your kit was the inspiration.  I only wish there was enough hood space on a mK1 to run it like you did.  Oh well, it's only $134 more in piping.

[GEE-BEE]

It wont matter as the hard pipe is phrone to heat soak, feel it when your done..

Stephansautohaus had the same problem until I took what they were using and made on complete silicone assy

I plan on relocating battery, using mk1td airflilter assy,custom intercooler with both outlets on the same side
2' thickness will allow to still have a/c compressor if you notch the frame where the a/c compressor ...

http://forums.tdiclub.com/showthread.php?t=281944

[CrazyAndy]

Well i haven't bought any new pipe yet, so if you wanna talk business just reply to my IM and we can set something up.
 I do like your idea with your AWIC setup; I just wanted to keep my battery in the same place since I figured on using this thing every day when I started to build it and wanted all the trunk space minus a small sub, so I'm still building it to that ethos.

[CRSMP5]

does not look like it ready fo rroad trip yet... guess mk3 tdi is ride to ohio this week huh..

when in post office setting up mail.. sending off electric company deposites and such.. saw something and thought of you.. nathan has at shop

drive safe.. see you tuesday.. towing my coupe down to new place you will getta see it.. just happy i can drive thru new place so i no have to push it in door.. unless they filled my place while i was gone..

[CrazyAndy]

Time again for another Rabbit Update. This time, AWIC water circuit plumbing!
After thinking about the routing of the air to water intercooler's water hoses, I decided to run both cooler radiator lines under the oil cooler since there's enough room to fit them without kinking the bends like passing the upper hose over the oil cooler would have done. I also found a pretty good way to mount the water pump using an expanded metal pipe hanger. If I get any undue noise from the pump through the body, I'll go back and put a strip of rubber either around the pump body or where the strap attaches to the inner fender well. I also used some pre-drilled bar stock to fab some basic AWIC core brackets, but there's still some wiggle room in case I need to adjust it to get the hoses to clear. The only line that did not want to bend without collapsing was the short line from the pump outlet to the core. I need to get another 3/4" elbow and clamps, and the system will be completed. The only concern I have is bleeding the system, but if worse comes to worse I can always use the capped end on the pump as a first-fill/bleed port.
I am about to order the rest of the silicone bends to complete the post-turbo side of the intake; I am (against gee-bee's wishes most likely) going to retain the metal pipe, but have decided to double wrap all the piping in foil heat tape to insulate them.  Now I just need to figure out where the filter will go. If a 180 degree silicone bend can go under the hood, I can run a pipe over the back of the engine near the firewall and mount a paper cone filter over the transmission. Anyone else have any other ideas? Only other issue I can see is still the 90 degree reducer exiting the core having to bend another 10-12 degrees, but the flex doesn't limit the internal diameter so I'm not really worried about it right now. If it does pose a problem, then I'll think about getting a mandrel-bent piece welded on in place of the original outlet or something like that.
Above all this, I just need to remember to mount and adjust my clutch cable and shift linkage before running a fartload of piping over them. After that it's just the downpipe and fan/pump wiring. It's happening!!!

[vanbcguy]

You are going to find you have a hard time getting the air out of the AWIC with it oriented the way it is. It takes a fair bit of futzing to get mine clear of air and my outlet is on the top.

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[CrazyAndy]

 I'm going to use a rad filler funnel to fill and air bleed the system initially; I also might try reversing the pump during filling so that the pump sucks water in from the core rather than trying to initially pull it through the hoses.  Don't worry, I know the system needs some work; if it doesn't get rid of all the air, I'll just try some rerouting and see what happens then.

[RabbitJockey]

why dont you mount your oil cooler like this 

[8v-of-fury!]

Hey Travidoodle, your car looks good with the fag-man on the cooler lololol.

[CrazyAndy]

Because Travy my boy I wish to never have to think, as I approach a curb or speed bump, the thought "I hope I don't lose oil pressure again!"  As an extension of that thought which I never want to think, the car will never be excessively lowered; I've put too much into her just to lose over 5 grand and 3 years to a quirky styling trait.

[Kazuki]

Lol nice

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[GEE-BEE]

Reminds of charter buses in mexico...

GB