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Thread: Intercooler below crash bar

  1. #1
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    Intercooler below crash bar

    Seen a few pictures on the 'sticky intercooler thread' of smaller front mounts that fit underneath the crash bar, thus avoiding having to cut it like the AH and welly cooler.

    Toyosport seem to have some reasonably priced ones. Anyone with one of these logged their intake temps? Or know how much power they are good for?

    This is what I'm on about: (sorry if I have nicked your picture)

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    too small for an S3...

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    Quote Originally Posted by <tuffty/> View Post
    too small for an S3...

    <tuffty/>
    So it's cut crash bar or nothing then?!

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    Uhhuh.

    ALL of us manly K03 boys run one of these beasts. Not suitable for a K04 though.
    I quite often say I'm going to do things.

    Then never do them.

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    I don't get why peeps are so hung up on cutting it tbh...

    If you want an intercooler that works then yeah cutting the crash bar will give you the room for a decent sized core... AH fabs V1, V2 and Welly cooler are all tried and tested S3 solutions... they just work..

    The smaller one you have pictured appears to work ok on A3's with smaller K03's

    <tuffty/>
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    Sorry to crash the thread, I'm looking at getting a fmic also, would the small core one from eBay be fine for what im after? I would only be fitting a k03 's' in time. Also where can you get the 2.5" pipe work
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    Quote Originally Posted by <tuffty/> View Post
    I don't get why peeps are so hung up on cutting it tbh...

    <tuffty/>
    Was nearly killed in a head on car crash many years ago (as a passenger) which was not much fun, so anything that weakens impact protection makes me nervous!

    But looks as though its the only way then to get a decent cooler.

  9. #8
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    The bumper bar offers no more crash protection than the old style metal bumper on a Mk1 golf... they are there to give substance to the styled/moulded modern bumper cars have these days...

    Can understand your reasoning and can't imagine what that must ave been like for you but in a situation like that the alloy 'crash' bar will provide nothing.. its designed to shrug off 'parking' bumps and thats about it...

    <tuffty/>
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    Quote Originally Posted by <tuffty/> View Post
    The bumper bar offers no more crash protection than the old style metal bumper on a Mk1 golf... they are there to give substance to the styled/moulded modern bumper cars have these days...

    Can understand your reasoning and can't imagine what that must ave been like for you but in a situation like that the alloy 'crash' bar will provide nothing.. its designed to shrug off 'parking' bumps and thats about it...

    <tuffty/>
    Many thanks tuffty, put my mind at ease, welly cooler is looking favourite now then
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    2.5" piping isn't a necessity.

    Mine is 2.25".
    I quite often say I'm going to do things.

    Then never do them.

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    I honestly think the front end of my car is stronger now it has a huge FMIC behind the puny so called "crash bar".

    Anyway, in my thread I have pics of when I tried running a FMIC similar to the size above alongside one of the stock smic and it just wasn't up to the job. Changed to the Welly core and now all is well in the world.
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    The crash bar is designed to crumple anyhow. That tank of an fmic we have will act as extra bracing to an extent..
    Quote Originally Posted by <tuffty/> View Post
    its either mapped or broken...

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    Sorry for being completely naive but can someone point me toward where I can purchase a wellycooler? Or even which cooler on the AH site is the V2? I can only seem to find the V1...

    Just looking around for my future Stage 2 mods.

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    I'm running a toyosports 550x225x64 Type R on mine. According to most of the people on here, who are in the know, its too small, yet my car has made 294bhp (ok its obviously a happy dyno), on stage 2, and I've never seen intake temps at more that 10deg above ambient.

    Generally, when on boost and giving it some, i'm seeing 6-7deg above ambient. I've not taken it on track yet, and its hard to really drive hard for sustained periods on the road, but I've done 25 miles or so, really ragging it, and when on the move, never managed to get intake temps any higher than mentioned.

    The reason I went for that cooler was more for fitment reasons rather than avoiding cutting the crash bar, but now that I've seen it fitted, it pretty much fills the lower bumper centre grill, so anything bigger will be getting no more airflow over it

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    Quote Originally Posted by vivalacoulter View Post
    Sorry for being completely naive but can someone point me toward where I can purchase a wellycooler? Or even which cooler on the AH site is the V2? I can only seem to find the V1...

    Just looking around for my future Stage 2 mods.

    Welly is a forum member who designed an fmic to fit and work. Its a universal cooler i believe. Look in the stickys bud. The ah is a different brand all together. Think they are better flowing for bigger turbo set ups.

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    Ok just to let you know,i had a wellycooler on.my golf when I crashed.when u went to get my parts of it.they guy at the recovery places said that massive cooler probably saved your life as it took the impact of the crash.:...just saying!
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    Word!!!

    My A3/Martys Golf would smash that, and this guys £7000 GT9743 supercharged love machine.

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    Quote Originally Posted by daz-20vt View Post
    Welly is a forum member who designed an fmic to fit and work. Its a universal cooler i believe. Look in the stickys bud. The ah is a different brand all together. Think they are better flowing for bigger turbo set ups.
    Okay, now I'm sure I'm being blind, can't find the wellycooler in the stickies! Or is it somewhere in the large thread on the AH Fab ones?

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    Quote Originally Posted by Paradox1 View Post
    Ok just to let you know,i had a wellycooler on.my golf when I crashed.when u went to get my parts of it.they guy at the recovery places said that massive cooler probably saved your life as it took the impact of the crash.:...just saying!
    Some mods I find hard to justify before I make payment and get them fitted....but I love this justification on why to fit a FMIC lol

    I'll remember this when I'm buying the bits and pieces I need in the next few months
    JudderMan likes this.
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    I would read the fmic sticky but try searching wellycooler as it may have been a thread now i think about it. Its defo about somewhere. Daz

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    Quote Originally Posted by JimS3 View Post
    Seen a few pictures on the 'sticky intercooler thread' of smaller front mounts that fit underneath the crash bar, thus avoiding having to cut it like the AH and welly cooler.

    Toyosport seem to have some reasonably priced ones. Anyone with one of these logged their intake temps? Or know how much power they are good for?

    This is what I'm on about: (sorry if I have nicked your picture)

    image.jpg
    There's one on the VAG Parts / Cars for sale Facebook page if you're looking to buy one - he will only accept cash on collection though - doesn't wanna post. AH Fabs V1 with all piping £150 - I wanted to but it was cost me that in fuel to drive there, iirc I think it Norfolk? Ill try and find the link..,.

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    Alex Ayers his name was.. From Lowestoft - so if you're not that far away from there it's a bargain :-)

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    Quote Originally Posted by JimS3 View Post
    Was nearly killed in a head on car crash many years ago (as a passenger) which was not much fun, so anything that weakens impact protection makes me nervous!

    But looks as though its the only way then to get a decent cooler.
    and behind the trimmed crash bar is..... oh dont tell me... erm... Oh I know.. a 76mm Thick aluminium, deformable intercooler...
    you think an aluminium crash bar has strength?
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    Quote Originally Posted by badger5 View Post
    and behind the trimmed crash bar is..... oh dont tell me... erm... Oh I know.. a 76mm Thick aluminium, deformable intercooler...
    you think an aluminium crash bar has strength?
    See your point.

    So a front mount is an essential safety upgrade... lol

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    Quote Originally Posted by 16Klappe View Post
    2.5" piping isn't a necessity.

    Mine is 2.25".
    it is on an S3. and neither your hotside, or your cold side pipes are 2.25''.

    Stop giving bad advice
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    Read the thread.

    I had previously confirmed this kit is only suitable for K03 cars, and my response was to grail who was the only person quoting 2.5" sizing.

    Pal.
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    Then never do them.

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    There really aren't any draw backs to the Wellycooler if you want a FMIC. There excellent VFM, good fun to fit and work very well. Why look for an alternative?

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    Quote Originally Posted by ReDBull View Post
    There really aren't any draw backs to the Wellycooler if you want a FMIC. There excellent VFM, good fun to fit and work very well. Why look for an alternative?
    i did it just to be different

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    Quote Originally Posted by vroomtshh View Post
    i did it just to be different
    Are you on SCN? Black LCR with sexy wheels?

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    Quote Originally Posted by ReDBull View Post
    Are you on SCN? Black LCR with sexy wheels?
    nah that's my mate John. I have the silver one with sexy wheels
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  32. #31
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    Quote Originally Posted by JimS3 View Post
    Thats the one.
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  33. #32
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    Quote Originally Posted by JimS3 View Post
    See your point.

    So a front mount is an essential safety upgrade... lol
    yea man
    consider it 76mm finned crumple zone.
    hehe
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  34. #33
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    Quote Originally Posted by Vex182 View Post
    Thats the one.
    Is the piping then the same as the AH Fab intercooler?

    EDIT:

    Found this, not to worry!

    'Wellycooler' fitting

  35. #34
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    Its Voids that save you in crashes not pieces of metal..

  36. #35
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    The most important function of the crash bar is to provide a crumple zone to protect the chassis legs, as already said when a large aluminium cooler is installed trimming of the bar really isn't an issue although any major cutting of this crash bar may reduce its ability to protect your chassis legs in an impact, while none of us ever intend to crash its worth consideration.
    Its good practice to avoid cutting any crash bar where possible but knowing the issues on big power S3 builds little other options are realistically available, if safety was truly in question I wouldn't but as only the condition of the chassis legs in the event of an impact is in question IMO bash on..

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  37. #36
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    Quote Originally Posted by 16Klappe View Post
    2.5" piping isn't a necessity.

    Mine is 2.25".
    Quote Originally Posted by 16Klappe View Post
    ALL of us manly K03 boys run one of these beasts.

    Speak for your self:


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  38. #37
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    The crash bar is also a structural piece of the car that connects the chassis legs and stiffens the chassis. What else substantial is there connecting the chassis legs if the bumper is cut. In a low speed shunt the bar would probably deform a little and save the rad, standard intercooler , and air con rad meaning the car could still be driven.
    Without it its liable your intercooler will be pushed through the rads at the front of the car.
    People are quite happy to add strut braces to increase stiffness but whats the point if you are removing something like the front bumper.
    I personally wouldn't cut the bumper bar or remove parts of it, but each to their own.

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