Air to Water Intercooling (good for tight spaces)

[myke_w]

Hey guys. I just took the plunge and purchased an air to water inter-cooler kit to solve some space problems in a mk2 tdi install (small bumper).



My Requirements Were:

Car must look stock from outside
Not willing to cut any contiguous body parts
Retain full size radiator in stock location
Mount must be clean, not interfere with other parts
Shortest pipe path available
 

I went around and around trying to find an appropriate FMIC or SMIC to fit the car with no real luck.

I played with rabbit td radiators (much shorter), several small intercoolers, different hose routes (same side and different sides) and really never found a solution that didn't create another problem that I could live with.

I started reading about air to water, and after years of thinking about how they "only use those at the drag strip", found that several stock vehicles have come equipped with them.

I finally saw a picture of zagarus's install yesterday that mimicked what I had in my mind.

ex.


I plan to document my install here, and welcome others to share their thoughts or build ideas.

[theman53]

My problem is A/C. I want to run it all and still have A/C. I need to get my round headlight core support and I will try to document mine. The more ticked off I am at thinking of things the less I take pics...

[myke_w]

I will not be running ac in the beginning. I'd like to eventually though.

I think creating a new mount point that sits further forward for the passenger lower radiator peg might help clear the compressor.
I know someone who did this in a mk2 and had good results.

Round headlights will help with space, I prefer the aero look with the de lights so I'm a glutton for punishment.

[theman53]

Well I will probably have an aero support when done. My lights/adjusters are trash on my areos so that wouldn't help you.
when I get my round core support I am going to try to make a bucket that bolts to the aero support. That way when you want to switch you can just bolt/unbolt them and add a new grill.   

Kind of in dream stage still

[CRSMP5]

you need to talk bob out of his odd ball hella de headlight set still... uses westy pa golf core support..

id also talk to ed abt the golf g60 he built in myron's garage back in 88/89ish.. has stock intercooler set up like a gtd by batt... room for ac and such.. no idea if he took pics why me telling you to ask him.. think if you used that set up idea for stock look.. but this style intercooler you will be good to go..

you should also bring the new ic over before puttint it on yours to see how/where it can fit in my 84.. for poo and giggles..  should have the 95 vr6 jetta inside in the next couple days to be gutted.. taken long enough.. finnally regained my garage space

[myke_w]

I figured it would'nt be long before you found this

I've gathered from everything I've read that the gtd intercooler setup was pretty much crap (no way to pull adequate flow over it.

I can always take it out and test mount it.

The key is going to be getting the brackets right to hold the damn thing, it's gonna be heavy with water in it

[foxracer1]

I plan to run an water-air cooler too. Will be watching your thread.

What size cooler did you get?

[myke_w]

I plan to run an water-air cooler too. Will be watching your thread.

What size cooler did you get?

The smallest one that I could find that does both in and out on same side.

ex. http://www.frozenboost.com/product_info.php?cPath=218&products_id=210&osCsid=ef06572d7d52f2612e4f639776638c85