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  1. #1
    tobycruse's Avatar
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    Cool Pro Alloy Intercooler (S3) - Fitting and Results with Pictures

    As some of you may know a while back I took my car to Pro Alloy to have a larger more efficient intercooler made and fitted to my S3.

    Pro Alloy is run by two guys, Wayne and Alex. Both of them are really nice and knowledgeable, talking to them for the first time I knew my car was in good hands!

    When Pro Alloy first had a look at the OEM intercooler set-up on the S3 they immediately realised they didn't have much space to work with. They almost aborted the project all together as they didn't think they could improve much on the original cooler.

    But upon closer investigation they realised they could make an intercooler approximately 10% - 12% bigger and one much more efficient in design. By this I mean it would cool more efficiently by letting air pass though it, both across the fins and through the cooler itself more effectively.

    So fabrication begun and before i knew it the new intercooler was fitted and testing began. Wayne begun data logging the manifold temps and comparing them to ambient temps. The results were impressive!

    OEM Intercooler Results
    Ambient Temp 26C
    Inletmanifold Temp 36C :o

    Pro Alloy Intercooler Results
    Ambient Temp 26C
    Inletmanifold Temp 28C :D

    Only 2C above ambient!

    At this point I came to collect the car and take it for a drive myself. The difference was amazing! The car had much better throttle response and is so much more keep through the rev range.

    Though the car "felt" better, I needed the actual power figures! So off to AmD I went. Had a 4 wheel alignment and two runs on the rollers!

    Before the new intercooler:
    365 Bhp 345 lb/ft @ 10.5C

    Pro Alloy intercooler
    372 Bhp 353 lb/ft @ 20.1C

    The most amazing thing about these results is that the car produced more power when the ambient temperature was 10C hotter! The guys were speculating that had the ambient temperature been the same the car would have been making closer to the 380 Bhp mark!

    Here you can see that the inlet pipes are much smoother, allowing air to enter and leave the cooler much more efficiently. Also, you can see how much bigger the Pro Alloy cooler it.




    A/C radiator in front of the cooler.


    The power figures at last!
    [img]http://lh6.ggpht.com/_-fkuaZ1b164/Sji6hGYdJPI/AAAAAAAAAq8/U***9PJMmzc/s800/16.06.09%20Remap.jpg[/img]
    Who said speed kills!?!?....But dangerous driving on the other hand....
    Ibis White S3 Sportback - ?bhp - ?lb/ft (Being Fixed)
    Mods: LED's Throughout, Milltek TBE, Revo S2+, Forge CAI (Gold), K&W V3's 25mm, H&R ARB's, Powerflex Bushes, Autotech HPFP, Sachs Clutch, Forge DV, Jonny's PCV Mod, Defi Boost Gauge, Pro Alloy Intercooler, 18" OZ Alleggerita's, NGK Iridium Spark Plugs, VI Performance Monitor, Road Angel Pro Connected
    Full OEM Springs and Shocks for sale from 2008 S3 CLICK ME

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  3. #2
    gixxer600k4's Avatar
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    how come there is a big loss in wheel power? on dyno sheet its says:

    before intercooler

    engine pow: 365bhp
    wheel pow: 303bhp

    after intercooler

    engine pow: 372bhp
    wheel pow: 274bhp

  4. #3
    gixxer600k4's Avatar
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    how come there is a big loss in wheel power? on dyno sheet its says:

    before intercooler

    engine pow: 365bhp
    wheel pow: 303bhp

    after intercooler

    engine pow: 372bhp
    wheel pow: 274bhp

  5. #4
    tobycruse's Avatar
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    Quote Originally Posted by gixxer600k4 View Post
    how come there is a big loss in wheel power? on dyno sheet its says:

    before intercooler

    engine pow: 365bhp
    wheel pow: 303bhp

    after intercooler

    engine pow: 372bhp
    wheel pow: 274bhp
    The machine was calibrated differently on each run, there is no loss of wheel power!
    Who said speed kills!?!?....But dangerous driving on the other hand....
    Ibis White S3 Sportback - ?bhp - ?lb/ft (Being Fixed)
    Mods: LED's Throughout, Milltek TBE, Revo S2+, Forge CAI (Gold), K&W V3's 25mm, H&R ARB's, Powerflex Bushes, Autotech HPFP, Sachs Clutch, Forge DV, Jonny's PCV Mod, Defi Boost Gauge, Pro Alloy Intercooler, 18" OZ Alleggerita's, NGK Iridium Spark Plugs, VI Performance Monitor, Road Angel Pro Connected
    Full OEM Springs and Shocks for sale from 2008 S3 CLICK ME

  6. #5
    Staz's Avatar
    is a retronaut

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    Good results! How much would it cost to have fitted though?
    8P2 S3

    For advice on Air Con problems please read my FAQs.
    To find ASN members with VCDS check out the MAP.

  7. #6
    Ash B's Avatar
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    Great Result! Intercooler looks a lot bigger than the standard one.
    Bet the car feels a lot better now! IF you dont mind me asking how much did it cost?
    Great Car Toby when will the modding stop ha!
    Enjoy the car

    Thanks

    Ashley
    Dark Vader Half sibling - MyThread

  8. #7
    MarkSport's Avatar
    A3 2.0TDI 170bhp PhantomBlack

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    Quote Originally Posted by benskin07 View Post
    Great Result! Intercooler looks a lot bigger than the standard one.
    Bet the car feels a lot better now! IF you dont mind me asking how much did it cost?
    Great Car Toby when will the modding stop ha!
    Enjoy the car

    Thanks

    Ashley
    x2
    2007 Audi A3 | MB POWERED | ECS TAI | Eibach Pro-Kit | 6000k & Leds | Vag-Com Coded
    Custom DeCat Exhaust 2,5'' | Nitroplus | RNS-E w/2010 AN

  9. #8
    tobycruse's Avatar
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    Price is ??????

    Its being sorted out between AmD and Pro Alloy.... So watch this space!
    Who said speed kills!?!?....But dangerous driving on the other hand....
    Ibis White S3 Sportback - ?bhp - ?lb/ft (Being Fixed)
    Mods: LED's Throughout, Milltek TBE, Revo S2+, Forge CAI (Gold), K&W V3's 25mm, H&R ARB's, Powerflex Bushes, Autotech HPFP, Sachs Clutch, Forge DV, Jonny's PCV Mod, Defi Boost Gauge, Pro Alloy Intercooler, 18" OZ Alleggerita's, NGK Iridium Spark Plugs, VI Performance Monitor, Road Angel Pro Connected
    Full OEM Springs and Shocks for sale from 2008 S3 CLICK ME

  10. #9
    MarkSport's Avatar
    A3 2.0TDI 170bhp PhantomBlack

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    And what dimensions it has?
    2007 Audi A3 | MB POWERED | ECS TAI | Eibach Pro-Kit | 6000k & Leds | Vag-Com Coded
    Custom DeCat Exhaust 2,5'' | Nitroplus | RNS-E w/2010 AN

  11. #10
    devonmikeyboy's Avatar
    As far from JBS as possible !

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    I would be interested as i was going to get an S3 FMIC fitted as part of my rebuild but need a price.
    06 Audi 2.0 PD140 Sport TDI Quattro S-LINE.
    Old engine 330 bhp @ flywheel 263 bhp @ wheel 490 lb torque. Audidriver write up HERE
    Now stripped and playing with an uprated Cryo treated engine fitted with bigger turbo,water/methanol,uprated injectors etc etc.Wanting 400 bhp and 500 lb torque.

    Other car 500+ bhp MK4 Golf R32 turbo.

 

 

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