Intercooling

[snakemaster]

2 blowing 350?  what power did that put out , that car would be slick at glames with a set off paddles

[745 turbogreasel]

They recon about 2000HP.  No 350, it's two Olds Toronado 425CI powertrains.
Well covered on the web if you search 'Hurst hairy Olds'

/threadjack

[R.O.R-2.0]

They recon about 2000HP.  No 350, it's two Olds Toronado 425CI powertrains.
Well covered on the web if you search 'Hurst hairy Olds'

/threadjack

i thought they had 455ci engines, and TH425 transmixer tho?

[R.O.R-2.0]

nope. they had both according to wikipedia..

[CrazyAndy]

A far as radiators, you could just double up on two stock GTI units.  Since the exits for the coolant hoses are on the same side, just use the one in the front for the AWIC and the rear one set 1-2" to the driver side for the engine.  Run the engine coolant pipes through the exhaust tunnel like you said, and voila!

And as far as integrating the AWIC into the intake manifold, I have seen it done on the vortex before.  It was done to an ABA w/ a Neuspeed supercharger by cutting the intake between the SC and where the intake runners turn to go into the head (link: http://forums.vwvortex.com/showthread.php?5866260-Custom-Neuspeed-Supercharger-for-ABA-OBDII).  You could use a TD or PD intake to do the same thing, or better yet do it to a non-turbo 1Y manifold by welding the original intake port shut, cutting the long side open facing the front and weld a wide thick AWIC radiator area in.  Kinda like what the ABA guy did.

[R.O.R-2.0]

A far as radiators, you could just double up on two stock GTI units.  Since the exits for the coolant hoses are on the same side, just use the one in the front for the AWIC and the rear one set 1-2" to the driver side for the engine.  Run the engine coolant pipes through the exhaust tunnel like you said, and voila!

And as far as integrating the AWIC into the intake manifold, I have seen it done on the vortex before.  It was done to an ABA w/ a Neuspeed supercharger by cutting the intake between the SC and where the intake runners turn to go into the head (link: http://forums.vwvortex.com/showthread.php?5866260-Custom-Neuspeed-Supercharger-for-ABA-OBDII).  You could use a TD or PD intake to do the same thing, or better yet do it to a non-turbo 1Y manifold by welding the original intake port shut, cutting the long side open facing the front and weld a wide thick AWIC radiator area in.  Kinda like what the ABA guy did.

josh was planning on building an A2W intermanicooler as well... that was a while ago as well.

[8v-of-fury]

www.frozenboost.com

[vanbcguy]

www.frozenboost.com

I got my AWIC from those guys.  I've been very very happy with it!

[8v-of-fury]

Did you buy their "kit" or did you make it up yourself?

[scrounger]

I have been thinking about (not building yet) a long narrow intercooler at the root of the windshield in the area where the windshield wiper mechanism is.

It is a high pressure area.

[vanbcguy]

Did you buy their "kit" or did you make it up yourself?

I bought their kit, the "600HP" kit.  I changed the intercooler to the 'straight through' one and mounted it above the transmission.  I also upgraded to the Bosch water pump (hey, Bosch parts on a VW? Who'd have thunk it?) and I got their hose and fittings kit.

In the end I didn't have enough room for the fan on the intercooler rad.  It hasn't been a big issue at all though.  The intercooler rad is about as big as my engine rad so even just with passive cooling it has more than enough area to cool down the boost water.  The engine rad is still mounted in the factory position at the bottom but I had to move the top back by about an inch and a half to fit the intercooler rad in front.  I've got the IC pump mounted on the frame rail at the low point in the system.  Thus far I have had no issues with it whatsoever.

I have a small "burp" tank on the exit side of the AWIC.  That ensures any air bubbles leave the system rather than circulating through over and over.  Mine is a little hokie - I used a Princess Auto plastic paint mixing can with some plastic fittings epoxied on to it.  It's been a year and a half since I put it in though with no problems.

It works really well - there's not really any way I can heat soak it.  The post-AWIC pipe is always cold to the touch while the pre-AWIC pipe is often too hot to keep your hand on it after you've been boosting a lot.  In fact the silicon couplings have changed colour a bit on the "hot" side while they still look brand new on the "cold" side - pretty definitive proof that there's a big temperature differential there!  I have a meat thermometer in my burp tank - at worst I see about 10-15°C over ambient there, but remember that is the exit side of the AWIC so it is "hot" water.  I can't find the calculation any more, but I believe the exit temperature from a K24 at 25PSI at 20°C ambient will be over 100°C.  Exit temperature from the AWIC is pretty darn close to ambient again.  Naturally the only way I can really measure that is to boost up a big hill then pull over and pop the hood.

[CrazyAndy]

Vanbcguy, care to show some pictures?  I might have been sweating over how to mount a AAIC in a MK1 for all this time when It might be better to run air-water.  Might even use my own suggestion with the '2 rads' thing.  The AWIC roll bar idea is great also; paint black for optimal dissapation, with good area on the bar for shedding heat.

[vanbcguy]

Sure!

Here's the kit:



Test fit:



Inside of the AWIC:



Installed:



AWIC Radiator installed:

[scrounger]

Have you had it long enough to measure any fuel economy change?

[8v-of-fury]

Have you had it long enough to measure any fuel economy change?

I am going to assume that with the size of that radiator and their claim to cool intake charge to near ambient (as Bryn has said it does to within a few degrees or so) that is has caused a substantial increase in efficiency!