T5 Intercooler Options

[MultiplexMan]

Now that my T5 is out of warranty I`m slowly starting the mods.

I`ve been following the progress of various improved intercooler solutions for the T5. The Forge unit looks like the go compared to the Allard unit - perfect fit into existing hoses, utilises the same mounting points and much larger effective area. Users are reporting improved fuel consumption figures and a modest increase in torque.

I don`t mind paying the price for the unit but the freight - GBP150!

Anyone recommend a local solution or better still a good freight alternative from the UK?

Cheers, MM

[Transporter]

How much is the intercooler? I would be interested.

[MultiplexMan]

Forge Motorsport | Alloy Fabrication

GBP475 + revised freight of GBP100. I'm close to pulling the trigger now.

The packed unit is huge: 104cm x 40cm x 22cm, weight of 11kg.

Want to try for a group discount?

[Transporter]

Forge Motorsport | Alloy Fabrication

GBP475 + revised freight of GBP100. I'm close to pulling the trigger now.

The packed unit is huge: 104cm x 40cm x 22cm, weight of 11kg.

Want to try for a group discount?

Hmm, if it would fit a new 2.0L TDI as well, we could try. But I don't think that it would be too much of the interest especially with the time of the year. For me it would have to be here by the 20th December, so I would have the time to fit it during the Christmas brake.

[brasstinman]

There's a garage down in Melbourne that specialises in VW modifications, i.e chips and performance etc.
They were in the VW Australia magazine 2 or 3 issues ago and had an article on a Golf GTI.
I'll see if I can dig it out, might be worth at least speaking to them.

[MultiplexMan]

I just pulled the trigger on this. AUD/GBP exchange is looking good and there was a discount too.

I should be fitting it in January...

[MultiplexMan]

I received a message from home. UPS delivered the intercooler yesterday.

I cannot wait to have a look - another week until R&R and installation.

[Greg Roles]

Mate while you're in there, do what you can to duct the intercooler to the front of the van, seal the edges at the very least!. Air takes the path of least resistance, so all the gaps round the sides makes for a less effective intercoolr, certainly following Polar's lead and using Alloy sheet from Bunnings with some Alloy reinforcing made a very measurable difference - where I was reading 5-20 degrees over the "ambient" on the intercooler outlet before, it dropped an average of 5 degrees with ducting, so when on the move on a hot day, inlet and outlet were equal, which wasn't the case stock.

[MultiplexMan]

Greg - I did the same on my tiny Daihatsu Copen - measurable difference!

I had industrial thermocouples before and after the intercooler and it was interesting to monitor. From memory I did get ~ +5 deg C delta-T (outlet temp vs inlet temp). Some fellows in Japan, popped out a front fog light fitting and installed a dedicated cooling duct - this gained a couple extra degrees.

I lagged and insulated the pipework from the turbo to minimise radiant transfer and soak. Fitting insulating spacers helps stops direct heat transfer.

It is a fine balance as you do not want to cook the turbo trying to keep the rest of the engine cool. I am not a fan of turbo bags.

Autospeed (Julian Edgar) had a couple articles that were great reading when I was researching.

[mariusau]

Hi there, just wondering if it makes any difference with the new intercooler. Have you done any more mods, like exhaust, engine management upgrade, cip box, other? I`m looking to get some more HP too, as after loading my tools in the T5 is seems to pull not as great as it did it before and the fuel consumtion rises too. Thanks.