1. This site uses cookies. By continuing to use this site, you are agreeing to our use of cookies. Learn More.

Pro Alloy Intercooler (S3) - Fitting and Results with Pictures

Discussion in 'A3/S3/Sportback (8P Chassis)' started by tobycruse, Jun 17, 2009.

  1. tobycruse
    Offline

    tobycruse Member

    Joined:
    Jul 21, 2004
    Messages:
    289
    Likes Received:
    0
    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 :eek:

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

    Only 2C above ambient! :rock:

    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.
    [​IMG]

    [​IMG]

    A/C radiator in front of the cooler.
    [​IMG]

    The power figures at last!
    [​IMG]
    #1
  2. gixxer600k4
    Offline

    gixxer600k4 Member

    Joined:
    Feb 19, 2009
    Messages:
    692
    Likes Received:
    0
    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
    #2
  3. gixxer600k4
    Offline

    gixxer600k4 Member

    Joined:
    Feb 19, 2009
    Messages:
    692
    Likes Received:
    0
    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
    #3
  4. tobycruse
    Offline

    tobycruse Member

    Joined:
    Jul 21, 2004
    Messages:
    289
    Likes Received:
    0
    The machine was calibrated differently on each run, there is no loss of wheel power!
    #4
  5. Staz
    Offline

    Staz is a retronaut Staff Member Moderator

    Joined:
    Oct 26, 2006
    Messages:
    6,189
    Likes Received:
    47
    Good results! How much would it cost to have fitted though?
    #5
  6. Ash B
    Offline

    Ash B Well-Known Member

    Joined:
    Jul 19, 2008
    Messages:
    5,829
    Likes Received:
    73
    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
    #6
  7. MarkSport
    Offline

    MarkSport A3 2.0TDI 170bhp PhantomBlack

    Joined:
    May 5, 2009
    Messages:
    126
    Likes Received:
    0
    x2
    #7
  8. tobycruse
    Offline

    tobycruse Member

    Joined:
    Jul 21, 2004
    Messages:
    289
    Likes Received:
    0
    Price is ??????

    Its being sorted out between AmD and Pro Alloy.... So watch this space!
    #8
  9. MarkSport
    Offline

    MarkSport A3 2.0TDI 170bhp PhantomBlack

    Joined:
    May 5, 2009
    Messages:
    126
    Likes Received:
    0
    And what dimensions it has?
    #9
  10. devonmikeyboy
    Offline

    devonmikeyboy As far from JBS as possible !

    Joined:
    Feb 8, 2007
    Messages:
    1,246
    Likes Received:
    7
    I would be interested as i was going to get an S3 FMIC fitted as part of my rebuild but need a price.
    #10

Share This Page