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Thread: 'Wellycooler' fitting

  1. #1
    Welly's Avatar
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    'Wellycooler' fitting

    As I have been getting a lot of PM questions about these - thought it might be worth listing what is needed in a thread just about this particular cooler.

    For this fitting method you will HAVE to remove fog lights, and is for engines with inlet manifold with TB on the right hand side, and charge pipe layout as per the S3.

    Intercooler specs are 600 x 300 x 76mm.

    Piping needed:

    2 x 90 degree 76mm hard pipes with beaded ends.
    2 x 90 degree 76mm silicone elbows in your choice of colour - these will need adjusting to length during fitting.
    2 x 90 degree 76 - 63mm reducing silicone elbows in your choice of colour.
    2 x 63mm alloy joiners.
    2 x 76mm alloy joiners.
    1 x 76mm 250mm length of straight silicone hose in your choice of colour. This needs to be cut into 2 lengths of 125mm to go on the end tanks of the cooler.
    10 x 70 - 90mm jubilee clips
    2 x 50 - 70mm jubilee clips.

    Hope that clears things up...


    Last edited by Welly; 17th February 2012 at 12:04.
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    Wellyboots, you are quite literally my most favourite pikey in the entire world




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  3. #2
    Alais DJA's Avatar
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    What would make thie even better would be link's to the parts

    Pretty please

    Marcus

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    Prawn's Avatar
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    Marcus, didn't I give you a full write up on how to install it on an A3 with links to all the parts you needed as well?

    Wellys guide is useless for you on your A3, as the pipes are totally different!
    -------------------------------------------------------------------------------------------------

    Prawns TFSI Turbo'd 1.8T Track Car

    But I know nothing so ignore me.

  5. #4
    <tuffty/>'s Avatar
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    Can you add this to the FMIC sticky please mate and then link to it here? keeps it in one place

    <tuffty/>
    Silver 2001 AMK S3. Silver alcantara interior... now with added powarrrrrrrr, torques. VAGCOM + KII-USB. >> My build thread...

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    Alais DJA's Avatar
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    Quote Originally Posted by Prawn View Post
    Marcus, didn't I give you a full write up on how to install it on an A3 with links to all the parts you needed as well?

    Wellys guide is useless for you on your A3, as the pipes are totally different!

    Its not for me Mr. Prawn....purely for the general public.

    You guide is printed off at home / on top of the xbox / and ready for ordering.

    550 cc Injectors / Milltek Exhaust Manifold

    Forge Silicone / Goodridge Hoses / EBC A/R

    G60 SMF / Launch Control Map

    Powerflex Black A/R / H&R Anti-Roll Bars

    Carbon Wrapping / 104Db @5400 RPM

  7. #6
    Prawn's Avatar
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    Quote Originally Posted by Alais DJA View Post
    Its not for me Mr. Prawn....purely for the general public.

    You guide is printed off at home / on top of the xbox / and ready for ordering.
    That's OK then that took me bloody ages to write! haha.

    Long live the Wellycooler and all who bask in it's icy cold IAT goodness!
    -------------------------------------------------------------------------------------------------

    Prawns TFSI Turbo'd 1.8T Track Car

    But I know nothing so ignore me.

  8. #7
    Welly's Avatar
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    Quote Originally Posted by Prawn View Post
    Wellys guide is useless for you on your A3, as the pipes are totally different!
    I did put that it was for right handed TBs, but I guess it's the charge pipe! lol

    Quote Originally Posted by <tuffty/> View Post
    Can you add this to the FMIC sticky please mate and then link to it here? keeps it in one place

    <tuffty/>
    I have copied and pasted it in there dude.
    ------------------------------------------------------------------------------------------
    "Marriage is like a coffin and each kid is another nail."
    Homer Simpson

    Quote Originally Posted by Prawn View Post
    Wellyboots, you are quite literally my most favourite pikey in the entire world




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    Alais DJA's Avatar
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    Quote Originally Posted by Prawn View Post
    That's OK then that took me bloody ages to write! haha.

    Long live the Wellycooler and all who bask in it's icy cold IAT goodness!
    You heading to this meet in Beaulieu or however the **** it's spelt

    550 cc Injectors / Milltek Exhaust Manifold

    Forge Silicone / Goodridge Hoses / EBC A/R

    G60 SMF / Launch Control Map

    Powerflex Black A/R / H&R Anti-Roll Bars

    Carbon Wrapping / 104Db @5400 RPM

  10. #9
    Prawn's Avatar
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    [QUOTE=Welly;1498352]I did put that it was for right handed TBs, but I guess it's the charge pipe! lol

    [/QUOTE

    I know dude, A3 routing is totally different sadly, different charge pipe, different side on the TB. only bit that can remain the same is your hot side pipes from the core to the headlight become the A3 cold side pipes, routing from the turbo to IC is 100% different though.

    It's also worth pointing out that if you follow Westy or Sports tractors pipe runs, you can keep your fogs on an S3

    Quote Originally Posted by Alais DJA View Post
    You heading to this meet in Beaulieu or however the **** it's spelt
    I could do I guess! when is it? in aid of what? not got the track car back yet, so I'm unsure
    -------------------------------------------------------------------------------------------------

    Prawns TFSI Turbo'd 1.8T Track Car

    But I know nothing so ignore me.

  11. #10
    RyanGolfGTTDi's Avatar
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    Welly im looking at doign this the same way Sportstractor has.

    With 76 - 63mm reducers from intercooler, joining on to 90 degree alloy bends then 90 degree silicone bends connecting up. (plus i have one length of alloy joiner.

    10 x 50 - 70 mikalors

    and 2 x 70 - 90 Mikalors.

    Do you think I could use the cheaper Jubilees?
    Audi S3 MTM
    345 BHP, K26 Turbo - MTM Manifold, Downpipe and Milltek Cat Back
    Polished Inlet - Facelift Front & Rear - Black Badges, Welly FMIC, N249 Bypass,

    To Come - Anthracite Rs4s

    ------------------------------------------------------------------------

    FOR SALE:
    Audi S3 Genuine Chrome Mirror Caps. PM Me for Details




  12. #11
    <tuffty/>'s Avatar
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    Quote Originally Posted by RyanS3MTM View Post
    Welly im looking at doign this the same way Sportstractor has.

    With 76 - 63mm reducers from intercooler, joining on to 90 degree alloy bends then 90 degree silicone bends connecting up. (plus i have one length of alloy joiner.

    10 x 50 - 70 mikalors

    and 2 x 70 - 90 Mikalors.

    Do you think I could use the cheaper Jubilees?
    Use JCS Hi-Grips rather than T-Bolt clamps....

    <tuffty/>
    Silver 2001 AMK S3. Silver alcantara interior... now with added powarrrrrrrr, torques. VAGCOM + KII-USB. >> My build thread...

  13. #12
    woking rob's Avatar
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    Can u not mod and re fit the fogs on this install?

  14. #13
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    Whats the advantage to JCS High Grips Tuffty?
    Audi S3 MTM
    345 BHP, K26 Turbo - MTM Manifold, Downpipe and Milltek Cat Back
    Polished Inlet - Facelift Front & Rear - Black Badges, Welly FMIC, N249 Bypass,

    To Come - Anthracite Rs4s

    ------------------------------------------------------------------------

    FOR SALE:
    Audi S3 Genuine Chrome Mirror Caps. PM Me for Details




  15. #14
    <tuffty/>'s Avatar
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    Quote Originally Posted by RyanS3MTM View Post
    Whats the advantage to JCS High Grips Tuffty?
    In the context of std Jubilees they go tighter before the click of death but you get better feel for how tight they are before they go... if you see what I mean...

    In context of T-Bolt/Mikalor clips... these clips have not feel for how tight they are... all the ones I have seen are under tightened giving boost leaks or over tightened crushing pipes and subsequently giving boost leaks... not a real fan...

    I use nothing but JCS Hi-Grips at Bills and use them on my own car thats been pressure tested to over 2bar...

    One thing to note... if you get the click of death tightening a Jubilee style clip then bin it... end...

    <tuffty/>
    Silver 2001 AMK S3. Silver alcantara interior... now with added powarrrrrrrr, torques. VAGCOM + KII-USB. >> My build thread...

  16. #15
    Prawn's Avatar
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    Couldn't agree more here, JCS Hi-grip stainless clamps on EVERYTHING.

    You can get Zinc coated ones for a fraction of the cost, but stainless is the way forwards.

    HATE T-bar clamps
    -------------------------------------------------------------------------------------------------

    Prawns TFSI Turbo'd 1.8T Track Car

    But I know nothing so ignore me.

  17. #16
    finesse's Avatar
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  18. #17
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    Another vote for JCS hi grips. Well good innit
    Audi S3 1.9 GT30....




    ....that is all

  19. #18
    Chugger

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    Quote Originally Posted by woking rob View Post
    Can u not mod and re fit the fogs on this install?
    i managed to keep the fogs with the same cooler, not sure what i did different though.

    Anybody after more photos, heres an album i put together of my install

    FMIC pictures by rsvan2000 - Photobucket

    57 A3 2.0 TDI Sportback (140)

  20. #19
    <tuffty/>'s Avatar
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    Quote Originally Posted by woking rob View Post
    Can u not mod and re fit the fogs on this install?
    Quote Originally Posted by sportstractor View Post
    i managed to keep the fogs with the same cooler, not sure what i did different though.

    Anybody after more photos, heres an album i put together of my install

    FMIC pictures by rsvan2000 - Photobucket

    The thing to remember is there is keeping the foglights and keeping the foglights and the grilles for the OEM look...

    IIRC you did indeed keep the foglights but at the expense of the grilles... with the AH cooler I kept both...

    Obviously its personal choice vs expense etc at the end of the day...

    In fairness to him, before sportstractor did his then it was believed it was near impossible to keep fogs with a Welly cooler...

    <tuffty/>
    Silver 2001 AMK S3. Silver alcantara interior... now with added powarrrrrrrr, torques. VAGCOM + KII-USB. >> My build thread...

  21. #20
    Prawn's Avatar
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    Quote Originally Posted by RyanS3MTM View Post

    10 x 50 - 70 mikalors
    Just noticed this, you'll need 60-80's mate, 63mm pipe, 5 mm wall thickness on decent silicon, x2 is 73mm. I used 60-80's and they were perfect
    -------------------------------------------------------------------------------------------------

    Prawns TFSI Turbo'd 1.8T Track Car

    But I know nothing so ignore me.

  22. #21
    Chugger

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    Yep there is no chance of keeping the grills with this cooler, the outlets are far too big. I was thinking of trying to mount the fog surround part of the grill, not sure how it would look though
    57 A3 2.0 TDI Sportback (140)

  23. #22
    sambryant's Avatar
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    im seriously thinking of buying a wellycooler, so much bigger than my apexi cooler and cheap.

    BADGER 5 TUNED gt2871, 360bhp 360ftlb



  24. #23
    Prawn's Avatar
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    Do it Sam!

    It's the future!
    -------------------------------------------------------------------------------------------------

    Prawns TFSI Turbo'd 1.8T Track Car

    But I know nothing so ignore me.

  25. #24
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    This bad boy just loves to flow. I tried 3 different FMIC setups and this one smashed it.
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  26. #25
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    Im going to buy one in that case

    BADGER 5 TUNED gt2871, 360bhp 360ftlb



  27. #26
    RyanGolfGTTDi's Avatar
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    60-80mm for the 63mm pipe and 70-90 for 76mm?

    Quote Originally Posted by Prawn View Post
    Just noticed this, you'll need 60-80's mate, 63mm pipe, 5 mm wall thickness on decent silicon, x2 is 73mm. I used 60-80's and they were perfect
    Audi S3 MTM
    345 BHP, K26 Turbo - MTM Manifold, Downpipe and Milltek Cat Back
    Polished Inlet - Facelift Front & Rear - Black Badges, Welly FMIC, N249 Bypass,

    To Come - Anthracite Rs4s

    ------------------------------------------------------------------------

    FOR SALE:
    Audi S3 Genuine Chrome Mirror Caps. PM Me for Details




  28. #27
    sambryant's Avatar
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    just bought a wellycooler

    BADGER 5 TUNED gt2871, 360bhp 360ftlb



  29. #28
    Prawn's Avatar
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    Quote Originally Posted by RyanS3MTM View Post
    60-80mm for the 63mm pipe and 70-90 for 76mm?
    Yup

    because the joiner is 63mm internal, with 5mm thick silicon, the OD is 73mm, and the 50-70's are just too tight!

    Same for 76mm joints, add in the silicon and it's 86mm OD, so 70-90 clips needed
    -------------------------------------------------------------------------------------------------

    Prawns TFSI Turbo'd 1.8T Track Car

    But I know nothing so ignore me.

  30. #29
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    In march I'm going to install the new S3 intercooler... It's expensive but I can keep the fog lights. The problem with wellycooler it's the MOT here in Portugal
    Talking about the 800hp by 0-400 S3 : "Is it true that everytime you take this car down the strip, the earths rotation slows by 0.1 % ??"

  31. #30
    sambryant's Avatar
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    i fitted my wellycooler last night, what a beast to say im pleased with it is a total understatement.

    this is the cooler up against my 42" tv



    now fitted, no easy task like my old fmic but worth the extra effort




    now for the exciting bit.

    i did a run with my old apexi cooler a few weeks back when it was freezing.

    here is my peak torque, out side temps were -4c



    now here is a run i did today, outside temps were 11c




    i gained 15ftlb on a 15c warmer day how good is that. intake temps stay below 20c all day. im very very pleased. Bill i hope you read this as i might need to turn boost down even more lol
    limbo118118 likes this.

    BADGER 5 TUNED gt2871, 360bhp 360ftlb



  32. #31
    "Stick a V8 in it!"

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    Didnt someone fit one of these upside down, so the grilles and fogs could be retained?

    2000 A4 1.8T Sport Quattro Avant, Berry Pearl
    2000 A4 1.8T Sport Quattro Saloon, Black-ish
    1997 S4 - PPC £999 Challenge Track Car Build
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  33. #32
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    Very good.

    Although your cooler looks slightly diff to my welly cooler lol.
    Driving the most secretive S3 on ASN

  34. #33
    sambryant's Avatar
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    Quote Originally Posted by Dani_B19 View Post
    Very good.

    Although your cooler looks slightly diff to my welly cooler lol.
    same size cooler, mine has the correct size inlets

    BADGER 5 TUNED gt2871, 360bhp 360ftlb



  35. #34
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    Nice mate iv just bought one too cannot wait to fit iv got liquid gauge as well so see what my Reading say to my set up on standered map
    350bhp & 316ftlb BBT new k16 7+7 blade hybrid turbo, Welly cooler, jetex filter, relentless ported v3 manifold 3" downpipe & de-cat, liquid gauge, r32 rear arb, AGU ported and polished Head, 550cc injectors, kw v2 Coilovers, s3dave tie bars & heat sheild, milltek cat back, I.E forged rods, brembos, inline fuel pump, v3 badger 5 tip, devils own WMI kit, AGU pistons, rear grooved discs & brembo pads, ds2500 pads & EBC ultimax disc, stack boost gauge

  36. #35
    Dani_B19's Avatar
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    What, 63mm?
    Driving the most secretive S3 on ASN

  37. #36
    sambryant's Avatar
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    Quote Originally Posted by Dani_B19 View Post
    What, 63mm?
    64mm

    BADGER 5 TUNED gt2871, 360bhp 360ftlb



  38. #37
    Dani_B19's Avatar
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    What, where did you get that cooler from?
    Driving the most secretive S3 on ASN

  39. #38
    sambryant's Avatar
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    toyo sports. the only down side is the main fixings are on the under side of the cooler, there is one fixing point on the top

    BADGER 5 TUNED gt2871, 360bhp 360ftlb



  40. #39
    Dani_B19's Avatar
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    Ooh bugger, sod it, ive bought mine now, cant be bothered buying another lol.
    Driving the most secretive S3 on ASN

  41. #40
    sambryant's Avatar
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    i used some big brackets and still mounted it above the cooler. would have been much easier if the fixings were on top, but i do prefer having the correct size inlets, nothing wrong with 3" inlets just means using reducers.

    BADGER 5 TUNED gt2871, 360bhp 360ftlb



 

 
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