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Author Topic: Considering making front mount intercooler kits  (Read 20514 times)

March 17, 2006, 04:25:43 am

vwmike

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Considering making front mount intercooler kits
« on: March 17, 2006, 04:25:43 am »
As the title says, I'm thinking of making some front mount intercooler kits. For a start I'm thinking of making some kits for non A/C MK2's with the 1.6TD. I can go a few different routes, but I'd like to get some feedback on a few things.

#1 - who's interested?

#2 - I have many intercoolers of various size to consider. I could keep prices down by using an off-the-shelf intercooler, but I am concerned with how it may fare as I know some of you will be pushing a lot more boost then was originally intended. I would like this intercooler to be able to hold up to about 50 psi, but I wouldn't mind your input on it. If you are interested in this, would cost be more of a factor than the peice of mind should you decide to run insane amounts of boost?

#3 - I typically use aluminized mandrel u-bends to make charge pipes, but they could also be made out of aluminum or sanitary fittings. Steel is obviously the cheapest so the others would also affect the cost. Would anyone have a problem with steel?



Reply #1March 17, 2006, 03:07:02 pm

irdiver

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Considering making front mount intercooler kits
« Reply #1 on: March 17, 2006, 03:07:02 pm »
any hope for an a/c equiped version for an mk2 jetta td?
'91 jetta eco diesel - sold 10/06
currently looking for a new project

Reply #2March 17, 2006, 03:24:07 pm

vwmike

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Considering making front mount intercooler kits
« Reply #2 on: March 17, 2006, 03:24:07 pm »
Without a big bumper (90-92 style) there just isn't really any room for an intercooler unless we use an air/water setup. This would be more costly, but could also be more beneficial if you were to drag race the car. The non A/C setup would place the intercooler in front of the radiator where the A/C condenser would be. The radiator would already have to move back slightly as space is at a premium. The advantage is that a very large intercooler could fit and potentially be as big as the radiator (although I haven't been able to find one in those exact dimensions).

Reply #3March 18, 2006, 02:57:52 pm

irdiver

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Considering making front mount intercooler kits
« Reply #3 on: March 18, 2006, 02:57:52 pm »
humm well mine is the big bumper edition, '91, so what is the best idea for an intercooler?
'91 jetta eco diesel - sold 10/06
currently looking for a new project

Reply #4March 18, 2006, 03:35:21 pm

vwmike

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Considering making front mount intercooler kits
« Reply #4 on: March 18, 2006, 03:35:21 pm »
A 6" tall core in the front bumper with some cutting to the bumper cap and support would be the best way to make it fit. This is an 8" core:



There wouldn't be much crash protection left if that concerns you.

Reply #5March 19, 2006, 02:08:14 am

VolkSport

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Considering making front mount intercooler kits
« Reply #5 on: March 19, 2006, 02:08:14 am »
I would be potentially interested depending on cost.  I have an intercooler out of a Peugeot but it has plastic end tanks so I've been hesitant in putting it in.  I've also been flip flopping where to put it... infront of the rad would be the most efficient but space is limited so I looked into putting it above the tranny as a top mount with a scoop but that's boarderline honda civic.  I'd love a custom made one for our cars and steel is A-OK by me.  Do you have a ballpark price?
'60 Beetle
'85 Jetta TD
Dune Buggy

Reply #6March 19, 2006, 05:32:48 pm

vwmike

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Considering making front mount intercooler kits
« Reply #6 on: March 19, 2006, 05:32:48 pm »
I'd love to keep this thing as inexpensive as possible, but I'm not going to sell anything I wouldn't use myself. Looking at cost estimates it would likely be in the $600 range. That would include silicone connectors, T-bolt clamps, all the piping would be mandrel bent aluminized steel. All welds would be TIG'd, and all ends bead rolled. Any mounting peices for the intercooler would also be included.

Reply #7March 20, 2006, 08:18:05 am

Turbo DS

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Considering making front mount intercooler kits
« Reply #7 on: March 20, 2006, 08:18:05 am »
I've heard SSautochrome et al is considering making kits in the 2-300 range for our cars.  They seem to try to be covering all makes!

Reply #8March 20, 2006, 02:08:12 pm

vwmike

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Considering making front mount intercooler kits
« Reply #8 on: March 20, 2006, 02:08:12 pm »
That would be quite interesting. If they could offer a kit for $300 then there is no way I could compete with that price. Just be careful is all, you get what you pay for.

Reply #9March 20, 2006, 08:42:35 pm

DVST8R

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Considering making front mount intercooler kits
« Reply #9 on: March 20, 2006, 08:42:35 pm »
Remeber: "Poor people can't afford to be cheap"  :wink:
The Brett of the board...



The Dark Side of Beauty.[/i]

Reply #10March 21, 2006, 04:04:51 am

vwmike

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Considering making front mount intercooler kits
« Reply #10 on: March 21, 2006, 04:04:51 am »
Quote from: "DVST8R"
Remeber: "Poor people can't afford to be cheap"  :wink:


And what exactly does that mean?  :)

Reply #11March 21, 2006, 11:36:51 am

LeeG

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Considering making front mount intercooler kits
« Reply #11 on: March 21, 2006, 11:36:51 am »
"Poor people can't afford to be cheap"

It means the most inexpensive is not the cheapest in the long run.  Like a good pair of shoes for $100 that lasts for 10 years vs a $50 pair that last for 2.  Substitute oil filters, intercoolers etc for shoes.
'97 Passat TDI

Reply #12March 21, 2006, 11:57:13 am

vwmike

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Considering making front mount intercooler kits
« Reply #12 on: March 21, 2006, 11:57:13 am »
Gotcha  :wink:

Reply #13March 21, 2006, 05:30:45 pm

vwmike

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Considering making front mount intercooler kits
« Reply #13 on: March 21, 2006, 05:30:45 pm »
So far the interest doesn't seem overwhelming.

Reply #14March 21, 2006, 05:32:02 pm

BlackTieTD

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Considering making front mount intercooler kits
« Reply #14 on: March 21, 2006, 05:32:02 pm »
i'd be interested for a mkI but not for $600. i think a good idea might be for you to produce the piping, and supply the joints, for an existing intercooler that fits... from an audi, saab or something. then people can just grab one from a yard and use your piping to finish the job. that would be more useful to me.