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Engine Specific Info and Questions => IDI Engine => Topic started by: BioDieselVW on December 27, 2007, 05:27:12 pm

Title: Caddy Intercooler Install
Post by: BioDieselVW on December 27, 2007, 05:27:12 pm: So I have been wanting to intercool my 1.6TD in my 81 Rabbit Pickup for a long time now. Being that it is a A/C car and I live in Florida there was no way that was being removed to install the intercooler. So with that said space is a major obsticle. My first plan was to relocate my battery and install a Saab 900 Blackstone Intercooler, but I really didnt want to move the battery so I scratched that idea. Then a few weeks ago I was searching the MK1 classifieds on VWVORTEX and come across a MK1 w/ A/C Callaway Rabbit Intercooler and piping setup. Now this is for a 1.7 gasser but I figured it could be modified. Well after a day in the garage here is what I now have.
(http://i19.photobucket.com/albums/b200/BioDieselVW/004.jpg)
(http://i19.photobucket.com/albums/b200/BioDieselVW/002.jpg)
(http://i19.photobucket.com/albums/b200/BioDieselVW/005.jpg)
(http://i19.photobucket.com/albums/b200/BioDieselVW/007.jpg)
(http://i19.photobucket.com/albums/b200/BioDieselVW/009.jpg)
Title: Caddy Intercooler Install
Post by: Diesel Fumes on December 27, 2007, 06:29:33 pm: beautiful set up. How are the boost levels now compared to before installation?
Title: Caddy Intercooler Install
Post by: burn_your_money on December 27, 2007, 08:21:44 pm: I'd recommend a screen on the scoop, you don't want to be picking up rocks and birds and the likes.

Very clean bay 8)
Title: Caddy Intercooler Install
Post by: vanagonturbo on December 27, 2007, 08:40:28 pm: Any pics of the intercooler itself? Everything else looks really clean! Is that a G60 valve cover? Is it new? It looks just like mine but mine has the oil filler on the other end. The finish appears to be the same though.
Title: Caddy Intercooler Install
Post by: BioDieselVW on December 28, 2007, 05:09:33 am: The Intercooler piping is 2 inch. I noticed zero loss of boost or drop in psi on boost gauge. It seems to be working very well. I will look into a screen on the front of the scoop. I will look for a pic of the Intercooler its self but it is 12x8x3. G60 Valve cover and it was painted silver metalic. Thanks Paul
Title: Caddy Intercooler Install
Post by: BioDieselVW on December 28, 2007, 05:14:42 am: Here is the Intercooler Schematic from Callaway

(http://i19.photobucket.com/albums/b200/BioDieselVW/Mk1_ac.jpg)
Title: Caddy Intercooler Install
Post by: diffdude on January 03, 2008, 03:23:55 pm: BioDieselVW,
The 12x8x3 size is that overall or the core size?
Thanks.
Title: Caddy Intercooler Install
Post by: blkboostedtruck on January 03, 2008, 03:49:54 pm: Ahhhh your my idol! and i keep forgeting about those old calloway setups!
and i been scratching my head on how i'm gonna run an I.C. without moving my battery! looks nice! you should go back to your profile and add your location!
thanks Duane
Title: Caddy Intercooler Install
Post by: OM617 on January 04, 2008, 04:30:45 am: Very nice install. :D
Title: Caddy Intercooler Install
Post by: gldgti on January 05, 2008, 03:12:41 pm: nice - well done!
Title: Caddy Intercooler Install
Post by: Quantum TD on January 05, 2008, 03:25:18 pm: Nice! Any noticeable improvement in performance?
Title: Caddy Intercooler Install
Post by: Baselyne on January 05, 2008, 03:36:58 pm: what was your EGT before and after the inntercooler install?

are you running the stock exhaust?

very nice set up man, thats so motivating
Now if only the lot could find some calloway intercoolers...`
:roll:
Title: Caddy Intercooler Install
Post by: BioDieselVW on January 05, 2008, 04:58:32 pm: I have noticed a difference in performance. As far as egts my gauge was in my PP 2.5 downpipe. Im in the middle of moving it into the exhaust manifold while I install my exhaust stack 4 inch and redo my entire exhaust. So i will let everyone know my egts once its installed correctly and accurate. Thanks
Title: Caddy Intercooler Install
Post by: subsonic on January 05, 2008, 06:21:47 pm: Quote from: "burn_your_money"
I'd recommend a screen on the scoop, you don't want to be picking up rocks and birds and the likes.

Very clean bay 8)

Snow scoop :lol:

Like the lay out.
Title: Caddy Intercooler Install
Post by: BioDieselVW on January 05, 2008, 07:18:34 pm: I do agree it would be a snow scoop, but i live in florida and there isnt much snow here :D It would help to keep those egts down though.