Intercooler suggestions

[RunninWild]

Been searching a bit lately and I can't seem to find much information on what is needed/optimal in reguards to an intercooler. I bought a large evo 9 front mount intercooler for my build but it doesn't look like I'm going to be able to mount it without destroying my front clip, moving my steering box outside the frame or mounting it on the outside of my grill. An external mount would probably be too hillbilly for even myself and I'd run the risk of puncturing it in the Bush. And the amount of work in the other options isn't ideal. I should mention this is a 1.6td with aaz head and a k24 on a Giles pump in a Suzuki samurai with the intent of running 25ish psi. Will more then likely be upgrading to a he200wg in the future.

Working space I have roughly 20x6x2.5 +/-. There are some Chinese fmic's on eBay for around $200 that I could probably make fit but it's a bit more then I'd like to spend if I didnt have too. Are there any stock turbo's that people usually run with good results? I'm thinking maybe a tdi or a4 side mount intercooler mounted in front of the rad might fit and They can be had for fairly cheap but it's hard to find performance data on them. I don't really need the best intercooler just something that would be able to keep the egt in check at those boost levels.
Do our engines need huge high flow intercoolers or have people had good results with cheap low end solutions?

[theman53]

I use a 28x5.5x2 now and it works very well. It is a Chinese unit.

[jmaddocks]

FWIW, I'm using an ebay bar-and-plate intercooler, approx. 18" x 8" x 2.5" core with a 2.5" inlet/outlet.  I can't quantify whether it's sized "right" for the application, but EGTs are in check (i.e., it's probably big enough...), and lag is minimal (i.e., it's not too big).  Inlet air temp would be a better metric, but I don't have a good way to measure it.

[RunninWild]

Think I may have found one that'll fit. Its fairly small and not the ideal shape for my application but it *should* work. The outlet is a bit wonky so it might not but it's cheap and I'm gonna order it. 9.5x11x3.5 It is very high flow and supposed to be very efficient for its original application. Don't think I'll have any problems with it!

[dontdoemyourself]

If it is any help, I'm running a Passat 1.8t intercooler on my aaz vanagon. I pieced together some junkyard piping and connectorso from Saab, Volvo and Audi cars
It definitely makes a huge difference in the egt's.. I have an aircraft spruce probe and vdo gauge and I have to be full throttle going uphill and towing to see egt's over 1300*F but cruising 65 mph on flat ground they are around 800..  I think the size you ordered should help a ton!

[RunninWild]

How much boost are you running? I didn't win the auction so still trying to figure something out. Do the plastic end tanks have problems with 20-25psi on a regular basis?

[Ian0391]

I'm curious how much boost you have through that passat intercooler. I also have one on my aaz golf and I can't keep the hoses in with those clips on anything over 10psi

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[dontdoemyourself]

I don't have my boost gauge hooked up currently, but that is a task I need to get around to..  I am running a t2 turbo with a needle valve boost controller.. I supposed I'm hitting 14psi.. I doubt 25 psi would break the plastic end tanks, but I don't know that definitely.