Any harm in adding an intercooler?

[1slowvw]

Hey guys, well I got an intercooler for my 95 golf 1.9 AZZ, and I was gonna start working on it today, so i called my father to ask where I might acquire some cheap piping, because I am a broke student, and he said I should definatly not put this on my car.
Now I explained to him that there is nothing I know of that could go wrong by doing this but I figured i should ask the experts.
So if any of you know any disadvantage to adding an intercooler please let me know, not that I want to prove my father right but it never hurts to know the whole story.
1SlowVW

[Barry W]

There is no disadvantage to adding an intercooler assuming the intercooler is not filled with sand....  It's better for performance, better for engine efficiency, better for engine longevity and can help prevent bits of turbo from entering the engine if the turbo grenades.  It's a win, win, win, win situation.

Andrew

Any recommendations on size? or known better ones for sale?  or place to buy such a cooler?

[burn_your_money]

The only disadvantage that I can think of is if you get one that has miserable flow, which would result in less air getting to the engine.

Go to a muffler shop and ask to buy some 2.5inch piping or w/e size you need

[1slowvw]

Great guys, that is just what i thought, other then the turbo granade safety which is a point i have overlooked (which i shouldent have because I have alwready had one turbo fail).
As for the piping, I hope to go to a mufler shop the bends however is what I was having trouble tracking down. Im thinking il Use 2 inch radiator hose, unless anyone can give me a good reason not too.
Thanks for the quick replies guys, I would still love to hear if anyone has any downsides to adding a intercooler, other then the added wieght of tubing and the intercooler itself.
1SlowVW

[burn_your_money]

I mentioned a disadvantage...

ebay has silicon connectors which are great for IC plumbing I hear

[1slowvw]

Yeah I thought about the e-bay route, however I do not have 150 to spend on piping. So I'm trying to find a cheaper way of doing it.
1SlowVW

[veeman]

As others have said, it's definitely a win-win solution.  Lower EGT's, lower intake air temps for denser air charge, etc.

For piping, I did a system on one car I had by using junkyard parts.  I used some piping from an Audi 5000 turbo, but other parts / tubes can be had from other turbo cars like Saabs, Mitsubishi's, etc.  I had to cut parts of mine and use some imagination, but it can be done.

For the connectors, I've heard of people using radiator hose and even those rubber connectors people use on house pipes, but I cant' comment on their durability / longevity.   Using connectors that blow off / fail could be a disadvantage if it ends up leaving you stranded or with a car that doesn't run properly.  

You could maybe look for hoses from modern VW products like a 1.8T, G-60 or other imports.  I know that some of the 1.8T hoses are the proper diameter and can be cut to fit your application.   Have a look in the junkyard for ideas...   It's either that or save some cash up and do it right.  I know that when I did my setup on my 1.6TD, the silicone connectors and clamps alone were nearly $100 for good 4/5 ply ones.

[g-spec]

I bought a whole front mount intercooler kit on ebay for 170...came with 10 pipes all the silicon connectors (2 are 90 degree) and clamps!!!
the intercooler came with aluminum end tanks.....I havent installed it yet....but im sure its a nice set-up!!!!!!

My dad discourages me all the time not to modify the cars....but i cant resist!!!!

[wolfsburgnut]

The intercooler I put on my 95 AAZ Golf was an Audi 5000 unit and I used Saab 900 (I think) intercooler pipes.  I had to get 3 sets to finally get the right bends, but at 15 bucks a set I wasnt complaining, and they are aluminum too!  My setup looses about 2 psi from what I was getting with no intercooler but I dont think that is too bad.  Maybe it is?  But you can always compensate and turn up the boost.

Peter

[malone]

So if any of you know any disadvantage to adding an intercooler please let me know

An intercooler is overkill for a TD. Icicles will form around the valves and cause nasty piston interference... stick to what the VW engineers did; don't put an intercooler in your vehicle.

:lol: - seriously though, I concur with everyone else here. Intercooling is beneficial. The possible reason why VW didn't add an intercooler to TDs (they did to TDIs later) is they wanted to save on cost, and the TD's longevity is acceptable at factory power w/o intercooling.. there's still room for improvement, however.

Going from a stock side-mount intercooler to a larger intercooler in a 90hp TDI is not a big deal if you don't do significant mods.. but going from no intercooler to a properly fitted intercooler is a good improvement for a TD. If there are any cons for intercooling a TD, such as cost, the pros still easily outweigh them.

[wolfsburgnut]

As for the cost factor, if your patient and you like to slog throught the mud at your local wrecking yard there is a bonanza of 80s turboed cars you can get parts from ie Volvo, Saab, Subaru, Audi, insert favourite Japanese make here, Ford .....  Although I stick with European marques because I dont want to taint my car too much

[1slowvw]

I have no problem with wandering through muddy junk yards, in fact i love junk yards, however the junk yards in my neck of the woods(eastern new brunswick) dont stock nearly any saab,audi, or volvo, and turbo cars in general.
I'm open to suggestions as far as piping goes, but for now im just going to keep searching the net for images that will help me.
Thanks to everyone who suported me in my intercooler argument, and those who gave con's.
1slowVW