What intercooler??

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nailer

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hi guys after abit of info on what intercooler to use for 500bhp+, currently running the welly cooler but not 100% happy with the bumper fitting ect, Was looking at the airtec or the Wagner intercooler?

Any help or advice would help thanks all.
 
Hi,

As far as I'm aware there are only a handful of people running that sort of power on here. Firstly i would start with a detailed read through the stickies FMIC setups and obtain as much info as you can from there. Heres the link : http://www.audi-sport.net/xf/threads/ah-fab-ebay-forge-s3-a3-fmic-installs-image-heavy.75425/

Next i would try and speak with a couple of the big power running guys, andrew & tufty and see what they say. I think they are running AH FABS intercoolers with custom outlets but you would have to speak to them. Another shot may be to contact Bill @ badger 5 as he sees many high power cars and owns one with that sort of power as well. :footy:
 
The first post of the thread Adam linked you to has all the information you need. Tuffty is making close to 500hp and it's only the cams that are holding him back
 
What bhp you running Andrew? And have you kept the fogs? Well we have an account with airtec and they look real nice and bigger then mine just don't wanna for something thTs not gonna do the job.
 
I just received my airtec intercooler, and although I haven't installed it yet it looks different to the pictures I have seen. In the pictures there are two long silicone hoses, whereas I have received 4 (I think, maybe more) pieces of silicone with some alloy joiners...
 
Ah... You must have the old type contact airtec sure they will send you revised pipes what size is the cooler?
 
the old type? I didn't realise there were two versions. I brought it through awesomegti. I might ask them about it..
 
Yea Jen when I get home I'll libk both setups :) so contact them I would like to try the airtec but don't wanna waste money.

And the welly cooler isn't a brilliant fit with the 3" outlets if only they was 2.5" outlets because I have welded pipes in but still slightly pushers pumper away
 
nailer said:
Yea Jen when I get home I'll libk both setups :) so contact them I would like to try the airtec but don't wanna waste money.

And the welly cooler isn't a brilliant fit with the 3" outlets if only they was 2.5" outlets because I have welded pipes in but still slightly pushers pumper away
Click to expand...

Thanks mate that would be perfect. I'll upload a photo of what I got when I get home
 
badger5 said:
just run stroker TT we built.. Wellycooler. 540bhp, good aits
Click to expand...

Proven to work at over 500bhp. That's good enough for me.

Maybe upload a picture of how yours is installed nailer? Also worth having a look at how others have mounted theirs and pipework routes etc in the stickies thread.
 
synygesa.jpg


Above is a picture of the intercooler I received. Came in airtec bubble wrap but is different to the picture below (from awesome gtis website)


utyjehab.jpg


Any ideas?
 
I think it's the same as the stock piping, not sure what that is though. I have dropped it off to my factory unit, I will check tomorrow if you'd like
 
I have just emailed awesomegti now, so I will wait to see what they say before I install it. I'm not sure if the pipes I have received will fit or not as I haven't even had time to dummy it up. I will let you know how I get on though, the core itself is huge so I can imagine it's going to be quite effective.
 
Jenno007 said:
synygesa.jpg


Above is a picture of the intercooler I received. Came in airtec bubble wrap but is different to the picture below (from awesome gtis website)


utyjehab.jpg


Any ideas?
Click to expand...

Hi mate, its exactly the same as what I received a few weeks ago direct from airtec so it cant be an old design, I think thats how they are now.
Mine is on and works really well 61mm core? I think.

Steve
 
crazyhilife said:
Hi mate, its exactly the same as what I received a few weeks ago direct from airtec so it cant be an old design, I think thats how they are now.
Mine is on and works really well 61mm core? I think.

Steve
Click to expand...
well I spoke with airtec and they said they now make them all silcone to improve flow as described on there site, so that would suggest old style but unsure then :-( really wanna see performance tbh
 
well I spoke with airtec and they said they now make them all silcone to improve flow as described on there site, so that would suggest old style but unsure then :-( really wanna see performance tbh[/QUOTE]


In that case I'm as confused as you but I can say I dont have any complaints about the airtec except the cost and I like that you can keep the fogs so it still looks stock.
I just wish I'd done a before and after AIT's log

Steve
 
lol, its overpriced and isn't it significantly smaller than the welly cooler?

the wellycooler CAN look oem..

edit: ignore what i just said i didn't realise the latest revision of the AH fabs cooler was over £600, that's extortionate. The original was ~300
 
Last edited:
superkarl said:
lol, its overpriced and isn't it significantly smaller than the welly cooler?

the wellycooler CAN look oem..

edit: ignore what i just said i didn't realise the latest revision of the AH fabs cooler was over £600, that's extortionate. The original was ~300
Click to expand...

Yep that's why I haven't gone AH and as far as size goes am sure airtec is biggest?

Height 340mm
Width 750mm (680mm without pipe take off's)
Thickness 60mm
 
Well cooler might 'do the job' but a genuine garrett or bell core will be much more efficient and smaller in size to achieve the same or better results.
 
nailer said:
And the welly cooler isn't a brilliant fit with the 3" outlets if only they was 2.5" outlets because I have welded pipes in but still slightly pushers pumper away
Click to expand...

I'm running this = http://www.beachbuggyturbo.co.uk/fmic-600x300x76mm-with-25-outlets-211-p.asp

Managed to keep my fogs and if I went for black silicone hoses I could have had it looking stealth but I opted for blue ones :)

My cars only stage 2 at 282bhp/298lbfts so can't comment on how it performs at circa 500bhp though.
 
Gary_808 said:
Well cooler might 'do the job' but a genuine garrett or bell core will be much more efficient and smaller in size to achieve the same or better results.
Click to expand...
And why is that?

kwistof said:
I'm running this = http://www.beachbuggyturbo.co.uk/fmic-600x300x76mm-with-25-outlets-211-p.asp

Managed to keep my fogs and if I went for black silicone hoses I could have had it looking stealth but I opted for blue ones :)

My cars only stage 2 at 282bhp/298lbfts so can't comment on how it performs at circa 500bhp though.
Click to expand...

And surely this would do same job as welly cooler but with better fitting?
 
All wellycoolers are not created equal.

Some are tube and fin, some are bar and plate.
Some have radiused ends, some don't.
No doubt some have good turbulators and some don't.

Intercoolers are a compromise, if they have good turbulators it retricts the airflow abit but cools the air better.

Dan at Beachbuggy had same size cooler with 63mm inlet/outlet, i don't know when he's getting more in though.
 
antwan64og said:
All wellycoolers are not created equal.

Some are tube and fin, some are bar and plate.
Some have radiused ends, some don't.
No doubt some have good turbulators and some don't.

Intercoolers are a compromise, if they have good turbulators it retricts the airflow abit but cools the air better.

Dan at Beachbuggy had same size cooler with 63mm inlet/outlet, i don't know when he's getting more in though.
Click to expand...

Fair comment! And they are only 90 pounds they do a few on eBay with a choice of bar and plate and or tube and thin and am sure tube and thin was 100 instead of 90 so guessing cools better
 
nailer said:
And surely this would do same job as welly cooler but with better fitting?
Click to expand...

As antwan64og said above mate all the Welly coolers aren't the same so I wouln't want to confirm if it's as good, worse or better than the Welly.... I suppose that would come to light on higher powered cars - but personally it's doing what I need it to do at stage 2 and when Niki mapped it he didn't advise of any issues with the FMIC kit and it helped me get decent stage 2 figures with the mods I have.

I'd drop Dan (beachbuggyturbo) an email and ask if he knows if his cooler is being used on any 500bhp set ups and how there performing.
 
Bar and plate coolers usually weigh more and restrict airflow more (by having good turbulators) BUT in doing so cool the air better.

Tube and fin less usually less pressure drop but less cooling as a result.

So its a trade off
 
How is your wellycooler reduced to 63mm tubing.

The 76mm - 63mm 90 degree bends look like the best option, they're like £19 each.
 
antwan64og said:
How is your wellycooler reduced to 63mm tubing.

The 76mm - 63mm 90 degree bends look like the best option, they're like £19 each.
Click to expand...
Well mine are welded in but still slightly pushes bumper away looked a crap fit tbh with 63mm outlets that would be perfect! If it will flow same
 
Gary_808 said:
Well cooler might 'do the job' but a genuine garrett or bell core will be much more efficient and smaller in size to achieve the same or better results.
Click to expand...

No might about it

Many cars using Toyo type B core on high power.
low pressure drop, good aits

Its big and its heavy is its downsides. and latterly some odd looking, different construction cores have been touted as wellycoolers but have'nt worked well at all just to throw in a curve ball.
 
FYI

The Toyo type B is Bar and Plate and has radiused ends.
Also know as part IC5001, it is listed as being available with 2.5" and 3" inlets but no one seems to stock the 2.5" version
 
audi upgrades
I went for the airtec aswell and it came with the pipes like jenno007 even tho it stated 2 big blueys, i called airtek direct to make sure this kit lets me keep me fog lights - quality it does

all fits nice with lots of tweaking here and there - shame you cant see the airtec logo went for black cooler blue logo
 
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