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AH Fab / Ebay / Forge S3/A3 FMIC installs (image heavy)

Discussion in 'A3/S3 Forum (8L Chassis)' started by <tuffty/>, Jul 10, 2009.

  1. Mougge
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    Mougge Member

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    [Apr 17, 2012]
    This is my Wellycooler before installation, Note my mounts.

    Thought it might be useful to someone to see:)

    [​IMG]

    [​IMG]

    [​IMG]
  2. sportstractor
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    sportstractor Chugger

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    [Apr 17, 2012]
    Nice mounts!
  3. Rich196
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    Rich196 Member

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    [Apr 18, 2012]
    Does anyone know if a welly cooler will fit a 225 TT?
  4. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 18, 2012]
    You may wanna read the posts above mate...
    post #506

    <tuffty/>
  5. Rich196
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    Rich196 Member

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    [Apr 18, 2012]
    I saw that but being new to this thread and forum. I that cooler on the TT, a 100% welly cooler or is it modified for the TT? Sorry for the silly questions
  6. StaceyS3
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    StaceyS3 Well-Known Member

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    [Apr 18, 2012]
    It's not quite a welly cooler that was fitted iirc as had different inlets and outlets but I should be playing with a wellycooler on a 225 TT tonight working out piping methods and routes before ordering ;)
  7. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 18, 2012]
    All derived from a welly cooler though (as was the one we did for Lee's S3)... point is... physically it will fit... as for pipe work while Rosso TT did indeed have his pipes welded it would suggest that the cooler will fit.... from what I have seen there is room to run the pipes at the bottom but obviously until you try it its always difficult to say for sure

    There aren't many TT owners on here let alone ones that have modded their cars... you can be the first :)

    At the price its worth a punt...

    <tuffty/>
  8. Mougge
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    Mougge Member

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    [Apr 20, 2012]
    Evening!

    Began to mount my Wellycooler tonight but have encountered difficulties.
    Just before the intake sits a plastic tube with an air mass sensor, I guess it is.
    It must be removed when I install Wellycoolern. How does it affect the car can be no good?

    I work on the picture but appreciate the quick response!









  9. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 20, 2012]
    Erm... I am pretty sure you don't mean the MAF sensor thats for the turbo intake and goes into the air filter..... so.. that leaves the MAP sensor tube that sits between the headlight and the battery tray... you need to leave this in and the 'wellycooler' can be fitted with this in place... this is an important sensor and needs to be in place :)

    <tuffty/>
  10. Rosso TT
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    Rosso TT Member

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    [Apr 21, 2012]
    Hi rich, that is indeed a welly cooler 600x300x78 2.5'' inlet-outlet, most people on here have it with 3'' inlet-outlet i believe, i'm a steel fabricator so i did all the braketry and piping myself and still got headlights washer working (took me 3 full days to sort it outthough).
  11. Mougge
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    Mougge Member

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    [Apr 21, 2012]
    Now I've been at it for about a day with Wellycooler and it is not good at all.

    Has been cut down every single slang for having been too long.
    On the driver's side it looks very ugly and I guess it will not hold tight.
    Had to splice an original hose.

    Is it one of those difficult job for the rest of you too or am I just very unlucky?
  12. Ads_AudiA3
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    Ads_AudiA3 Member

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    [Apr 21, 2012]
    After reading lots about the FMIC fitted to different S3's and A3's does anyone know ;

    If I get a welly cooler for a AUM A3 1.8T, to mount it upside down to keep the fogs do I HAVE to get 90 degree pipes welded on or can you use silicone reducers at this point?
    Also, with the headlight washers, is there enough room to keep them or do you have to lose them? I want to keep it as OEM as possible on the outside.

    Also, I'm looking at routing the pipe work all under the car, so behind the radiator and back towards pancake? Any ideas on this?
    Thanks
  13. Sam_
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    Sam_ Down under

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    [Apr 22, 2012]
    Fitted the AH Fabs V2 yesterday. What a nightmare job it was getting the bumper to fit afterwards. I have some pics but they are mostly the same as the ones above. Parts I used:

    1x AH Fabs V2 cooler
    2x 63mm alloy 90 degree bends
    2x 63mm silicon 90 degree bends
    1x Original 30 degree 4 inch long hose from the OEM setup

    I' not 100% sure on which hose was used as I could use the original map sensor to SMIC hose as it was too short and it needed a bit of a bend to match up to the alloy 90 degree. The bumper still needs some more trimming and tweaking to fit underneath and I could only fit one horn in the end.

    The major problem I had though was the TB to map sensor tube hose would just not stay on at the map sensor end. The hardest end to reach of course! It was reminiscent of the B5 TIP fitting where the 90 degree silicon to turbo adapter clamp just kept sliding off. The first time it popped off was on the bloody freeway and the car was horrible to drive, jerking loads. It was pretty horrid. Everytime I'd refit it and it'd be perfect on all sides them WOOOOOSHHH when it tries to come on boost. Take some tools on the test drive would be my advice! I've had to refit the damn hose about 5 times but it seems to be holding 22.5psi now I've given both parts a good clean with alcohol cleaner. Touch wood it'll be fine for the commute tomorrow!
  14. Sam_
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    Sam_ Down under

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    [Apr 22, 2012]
    Bit on the large side:

    [​IMG]
  15. superkarl
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    superkarl MAN OF STEEL

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    [Apr 22, 2012]
    good work sam. but the more pics the better!

    did you use pipes with beaded ends? that should help stop pipes popping off.
  16. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 22, 2012]
    I normally end up removing the battery to get better access to the MAP tube/TB hose clip... its a right PITA!!... what clips did you use in the end? JCS Hi Grips are the better ones to use rather than T-Bolt ones....


    Yes it is :)

    Designed to be used with big turbos in mind ;P

    Good work though, trimming wise I removed stuff from the fog brackets for clearance

    <tuffty/>
    Last edited: Apr 22, 2012
  17. Sam_
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    Sam_ Down under

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    [Apr 22, 2012]
    It's the OEM map sensor pipe that's causing the beef. It's beaded but I think there was oil on it (just a tiny bit) and the SFS hose didn't really fit on square. It's been a right pain driving not knowing if you'll lose all boost!

    I'll get some more fitted pics but it was pretty similar to others during the fitting process.
  18. Sam_
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    Sam_ Down under

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    [Apr 22, 2012]
    I was tempted to remove the battery. Next time (tomorrow no doubt haha). Yeah that's what I trimmed. Need to a but more underneath and redrill the bottom screws and relocate the captive nuts things.
  19. Sam_
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    Sam_ Down under

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    [Apr 22, 2012]
    And yeah, I used the JCS? Hi grips based on your recommendation. I got 70-90mm but I think the size down would be better. Less excess...
  20. Pat
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    Pat Member

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    [Apr 22, 2012]
    think ill be ordering one tomoz
  21. Sam_
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    Sam_ Down under

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    [Apr 22, 2012]
    Just make sure you ask for the mounts round the same way as mine (Sam's) else you'll be in for a nightmare. He'll know what you mean when you mention my name (probably brings horrible memories).
  22. Kevheslop
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    Kevheslop Member

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    [Apr 23, 2012]
    Hey all. Im going to experiment, ordered what i believe to be the correct silicone and ally parts, after reading about the forge i/c kit working with the oem fogs because of the diameter of piping etc, ive gone for 45 degree reducers off the i/c to 51mm piping etc... Hopefully it will work, its worth a try in my eyes.. Hopefully if everything is there for the weekend i can attempt it..

    So if anyone lives near plymouth ...help lol
    adam8747 likes this.
  23. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Apr 24, 2012]
    a Boring but true..
    AH V2 has a total volume of 6.4ltrs
  24. Sam_
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    Sam_ Down under

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    [Apr 25, 2012]
    Ok so here's my vague attempt at an AH Fabs V2 fitting guide. It's very rough but should be enough.

    I used the Forge guide for removing the SMIC's, bumper etc. This can be found here:
    http://www.forgemotorsport.com/media/S3FMIC.pdf

    This helps with the removal process.

    So the unusual bits I needed/used were:
    - Angle grinder with 1mm cutting disc and sanding disc to clean up cutting and drilled holes (remember safety glasses/goggles)
    - Drill with 8.5mm drill bit

    Fittings:
    - 2 x 63mm 90 degree alloy bends
    - 2 x 63mm 90 degree silicon bends
    - 10 JCS Hi Grip clips - I used 70-90mm but I'd go a size down if I done it again
    - I used one of the hoses from the standard SMIC setup that was around 4 inches long and had a ~30 degree bend in it. This was to bolt to the map sensor pipe to the 90 degree bend on the passenger side.

    Here's the piping I used (I replaced the upper boost hoses, also no pipe from the standard SMIC setup):

    [​IMG]

    So once everything was off. I cut the crash bar to suit the IC. You can see I kept 20mm around the front edge. You could cut it straight across instead of following the curve but for ease I done it this way. Measure twice, cut once! The bar is still very strong, or strong enough at least. The cooler mounts to the underside of the crash bar with M8 bolts. I used stainless fittings as I didn't want rust. I used a 8.5mm drill bit.

    Here's the cut out:

    [​IMG]

    Here's the cooler mounted:

    [​IMG]

    Then I fitted the pipes. Pretty much as the photo showing all parts above. You need to re-use the pipe from the SMIC setup like I say.

    Next up was mounting the horns. The Forge guide and some on here say you can get away with the standard horn bracket but I could see no way to do it so I made up a bracket from 3mm alloy. Excuse the roughness, I took the pic before I cleaned it up!

    [​IMG]

    Then mounted both:

    [​IMG]

    I simply zip tied the air temp sensor (for the dash) to the crash bar mount as you can see above.

    Ok so now you're ready to refit the bumper (which is an arse). I had to cut the mounts for the fogs slightly but every fitment will be different here so its a trial and error case really.

    [​IMG]

    I also adjusted the two bottom mounts as Tuffty did in one of the first two pages on here. The captive nut ones. I cut a channel as wide as the captive nut and moved the mounts about 15mm forward. I also added a central screw as the bumper sat very pissed. Here it is before I did that:

    [​IMG]

    And the final end result:

    [​IMG]

    Pretty happy with it. Looks very OEM and I'm getting much lower IATs. With an ambient temp of ~20c, IATs are around 25c. I'll do some proper logging when I get a chance.
  25. Pat
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    Pat Member

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    [Apr 25, 2012]
    ordered mine today, been told theres a lil back log on them but hey ho
  26. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 25, 2012]
    Wondering if I should start calling it the 'tufftycooler' :whistle2:

    <tuffty/>
  27. StaceyS3
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    StaceyS3 Well-Known Member

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    [Apr 25, 2012]
    I'm sure it will help with flow and temps massively on your set up ;)
  28. Sam_
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    Sam_ Down under

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    [Apr 26, 2012]
    Haha well it's pretty true!! Cheers for your design ;)
  29. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Apr 26, 2012]
    make sure they weld the damn brackets on the right way round!
    yet another came in here with them backwards! ffs - how many times more will they still make them WRONG!
    eejits!!
  30. Sam_
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    Sam_ Down under

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    [Apr 26, 2012]
    Just got off the phone to Lars and he's assured me the jig has now been updated. I told him it fitted perfectly with the mounts swapped.

    Annoying that the jig was wrong but it's one of those things. The rest of the cooler is awesome. Fits well enough with minimal modifications as I've shown above!
  31. Sam_
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    Sam_ Down under

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    [Apr 26, 2012]
    Here's one of it at night, when you can actually see it!

    [​IMG]
  32. GrantP
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    GrantP New Member

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    [Apr 26, 2012]
  33. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 26, 2012]
    Looks like someone has used a cheap chinese core and copied the AH Fabs V1 cooler... and all my fitting instructions LOL...

    Might be ok but at the price I don't know... I don't think anyone here has bought one yet as generally people go for either the wellycooler or the AH Fabs V2 (tufftycooler :thumbsup:)

    If you get one then please post pics and logs :)

    <tuffty/>
  34. s3dave
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    s3dave TFSI Hybrid Supporter

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    [Apr 26, 2012]
    At least the brackets are the right way round so not a copy......;)
  35. Kevheslop
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    Kevheslop Member

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    [Apr 26, 2012]
    How much !!!!! I have just put pretty much the same kit together for approx £200 squid via ebay.. So they must be chuckling inside
  36. StaceyS3
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    StaceyS3 Well-Known Member

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    [Apr 26, 2012]
    I have just been with a friend fitting the "wellycooler" with 76mm end tanks to a 225 TT and can confirm that it will fit with a little grinding to the back of each of the side grills and we also chopped off the two mounting lugs on the bottom of the core to allow us to lower it a tiny bit more

    What i can say is though its a lot easier than the s3 with no crash bar cutting needed on his and can use silicon reducers

    I will post a write up next week at some point when we complete it as was asked by Rich196 to let him know if and how it fits :)

    Would have done it tonight but the numpty didn't order 2 of the pipes and wanted to use 2mm steel bar to hang it off lol
  37. Rich196
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    Rich196 Member

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    [May 10, 2012]
    Nice one looking forward to the write up, perhaps I can run my car to you and you can help me fit it hahaha
  38. Leeivo
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    Leeivo New Member

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    [May 18, 2012]
    Will this kit fit on a forge Intercooler from a golf mk4 I'm planning on fitting it to my s3 2001 amk
    Last edited by a moderator: May 18, 2012
  39. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [May 18, 2012]
    Had to edit your post as it made no sense...

    Are you asking if the Forge intercooler kit from a Mk4 Golf will fit an S3?

    If so then arguably no... its not a direct fit... the Golf kit is designed for 1.8t engines that have the inlet on the (UK) drivers side whereas the s3 is the other side and designed as a 'pass through' type of cooler...

    You would need to do some work (quite a bit I would imagine) to get it piped up and there are better solutions available... assuming the reason you ask is because you either have one or been offered one then personally I would leave it and use something more suited..

    <tuffty/>
  40. StaceyS3
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    StaceyS3 Well-Known Member

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    [May 24, 2012]
    As promised a few pics of the welly cooler on a TT 225 1999 model

    We didn't need to trim the crash bar at all but it was quite snug :)

    [​IMG]

    We trimmed the 76mm - 60mm reducers at the 76mm end to give more clearence

    [​IMG]

    [​IMG]

    [​IMG]

    Pics of it finished and an attept to get som photos of the pipes through the grills

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    The only cutting we did was to cut off the 2 bottom mounting lugs on the intercooler to allow us to get it as low as possible and used a flap disc to remove some material from behind the inner lower corner of each side grill :)

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