Well for the last few days i have been building my front mount intercooler for the pending IHI turbo upgrade.
I found a few designs of intercoolers but all were for golfs. I thought to myself that why pay someone twice the price for soething i can build myself and get alot more satisfaction out of!
I ordered the core, had Dave at Milltek supply me with stainles exhaust pipe and purchased LOADS of Mikalor clamps and silicone cnnectiors/angles .etc
I knew the route i would take so it was quite simple. Now on the A3, the turbo outlet and throttle body are on the same side which makes this job bit of a pain in the arse! Forge do a kit for the Golf, but this runs a pipe through the crash bar and that is different on the golf to the A3 so that ruled that one out. I could use the S3 kit, but this wuld mean replacing the inlet manifold, alot of pipes and also re-running the throttle cable which is something i really did not fancy doing!
Now pretty much all the kits ive seen for the golf require the bumper to be modified...i was hoping that i would get awy with not having to do this, but it was not the case. No big deal though! just a bit more CAREFUL work to do. Took me about 1 and a half hours just to get the bumper to fit back on! The intercooler, at present is VERY visible indeed but will be somewhat hidden... Will always know its there though!
Below are the pics of what ive done so far.
This is some of the pipework and the core itself. Pipework is before i chopped it.
Old and new!
The route ive taken.
Popping out to say hello!
Naked and feeling sorry for itself
Intercooler and pipework pretty much complete!
Out... (need to order another bit of silicone for the final connection
The (nearly!) finished product!
All that remains to be done is the connection between intercooler outlet and throttle body, and also need to get a couple of offtake welded onto the turbo pipe for DV and N75. Them im done.
Will re-mesh the bumper when its all complete!
Watch this space for updates!