Edition 30 Welly Cooler guide?

[cupra_matt]

Evening everyone.

Im preparing my ED30 for stage 2 plus and i need to get a welly cooler fitted.

I havent ordered anything yet but have a list of all the parts need, one question though is regarding the bayonet fitting, what size do i need for the hardpipe down by the crank pulley?

Also does anyone know or have pics of how much of the front panel needs cut away to mount the 600x300x76mm core.
Also will having a black cooler effect its performance in anyway?

Many thanks.

[Paradox1]

You dont really need an welly cooler but it will be the best intercooler for this setup and if you ever decide to go big turbo too.
The bayonet coupler you need is 63-64mm. I got min from creation motorsport for about 23quid.

I didnt have to cut any of the bumper when fitting mine, but the crashbar does neet cutting to fit so you may want to think about that.

Black paint wont affect how the cooler works but i think the vents on the from bumper are quite big so stones may cause chips on the paint.

Of course you could go for a direct replacement like ths, wagner, perni etc

[pudding]

I think Mighty Car Mods did a myth busting thing on black intercoolers.  I can't remember the outcome though 

Is a welly cooler like a little fridge for Wellington boots or something?

I think some folk get a bit too wrapped up in "For stage 2+ - You must have a 3" catback, you must have a massive intercooler, you must have grade 7 spark plugs, you must have Millers Nanodrive.....".  You don't NEED any of it, technically speaking.  But a bigger IC certainly helps keep heatsoak down, but the more volume the turbo has to fill, the more chance of lag etc.

[Paradox1]

I think Mighty Car Mods did a myth busting thing on black intercoolers.  I can't remember the outcome though 

Is a welly cooler like a little fridge for Wellington boots or something?

I think some folk get a bit too wrapped up in "For stage 2+ - You must have a 3" catback, you must have a massive intercooler, you must have grade 7 spark plugs, you must have Millers Nanodrive.....".  You don't NEED any of it, technically speaking.  But a bigger IC certainly helps keep heatsoak down, but the more volume the turbo has to fill, the more chance of lag etc.

I think the Might Mods test made minimum to no difference. The only reason id stray it is if I wanted it to be a sleeper etc

Welly was the name of the first guy to try it universal intercooler on audi sport forums, about 5 years ago now. just a bit of banter that stuck.

Yes I totally agree. people going with all these name brand parts make the price of stage 2 ridiculous.

When I fitted my welly cooler I definitely noticed more torque, but I also noticed there was a bit of lag too. but once the intercooler had filled up its pulled hard and nicely. You dont really.

Even those cheap Ebay twintercoolers do the job for stage 2.

In other words dont break the bank lol

[patpong_pete]

where is the best place for the pipe work on the welly toyosports intercooler
is it2.5 or 3 inch pipework
thanks in advance for reply

[Paradox1]

I got mine from Ebay. they seem alot more expensive than they used to be. was about 8quid per alloy pipe but now its like 12-15quid a piece. we had to cut some of the pipes down so the intercooler was sitting correctly. I think it was ASH silicone where I got them from.

its 3inch reduced to 2.5 from the intercooler

[pudding]

I think Mighty Car Mods did a myth busting thing on black intercoolers.  I can't remember the outcome though 

Is a welly cooler like a little fridge for Wellington boots or something?

I think some folk get a bit too wrapped up in "For stage 2+ - You must have a 3" catback, you must have a massive intercooler, you must have grade 7 spark plugs, you must have Millers Nanodrive.....".  You don't NEED any of it, technically speaking.  But a bigger IC certainly helps keep heatsoak down, but the more volume the turbo has to fill, the more chance of lag etc.

I think the Might Mods test made minimum to no difference. The only reason id stray it is if I wanted it to be a sleeper etc

Welly was the name of the first guy to try it universal intercooler on audi sport forums, about 5 years ago now. just a bit of banter that stuck.

Yes I totally agree. people going with all these name brand parts make the price of stage 2 ridiculous.

When I fitted my welly cooler I definitely noticed more torque, but I also noticed there was a bit of lag too. but once the intercooler had filled up its pulled hard and nicely. You dont really.

Even those cheap Ebay twintercoolers do the job for stage 2.

In other words dont break the bank lol

Ah right, so Welly cooler just means 'generic ebay cooler' ?  Never knew that, good info 

I like things to be simple and I'm not into chopping bumper irons and stuff either, so I just dropped an S3 intercooler in instead. The post 2010 one with plastic end tanks, which was about £230 from Audi when I got it. Cheap for OEM!  The all alloy one (with minimal gains, hence why Audi dropped it) is now about £450!  I haven't noticed any lag, but then it's not much bigger than the GTI one!

I also tried a turbo muffler delete and a bigger turbo discharge pipe (KO4), but those two made bugger all difference, so took them off!

I think there comes a point where some mods make zero to hardly any difference, but folk still fit them anyway because the internet says so 

[Paradox1]

Yeah I definitely agree. Like most people wsnt to own everything for the car. lol

I've spend bare minimum on my mods by not following the scene price for name brand parts.
E'g forge intercooler was 700quid and the ebay 1 was like 170??

Im your case id be tempted to get one of the Ebay replacement/drop in intercoolers. They apparently flow the same as the S3 and limits around 360ish like the s3 intercooler.

[pudding]

Cheers mate.  I'm only going Stage 2 at the most, so that's what....330-340hp?  That's plenty for me, so the S3 should suffice 

I need to sort the chassis out before going big with the hp anyway.  It can barely contain stage 1, let alone 2!

[cupra_matt]

Thanks for the input guys 

Im like many of you, i dont need named brands, but i do want the engine to perform at the best it can. Ive already ordered my 3.5 inch decat DP and am deciding which exhaust to go for, i like the look of the scorpion 3 inch cat back resonated system.

I already have ceramic coated revo intake and auto tech internals and running GIAC stage 1.5 with Revo stage 2 DSG map.

Im not planning on going big turbo, but i thought that in the past with my cupra and ended up having 3 different turbos on it before i settled 

Has anyone got any pics of the intercooler setup with the bumper off?

Thanks again for the help and advice.

[Paradox1]

I got a pic with the welly cooler if that's the 1 you meant?

It's actually massive lol  but I'll get a picture up tomorrow

[cupra_matt]

I got a pic with the welly cooler if that's the 1 you meant?

It's actually massive lol  but I'll get a picture up tomorrow

That would be great.

Many thanks

[Paradox1]

Cheers mate.  I'm only going Stage 2 at the most, so that's what....330-340hp?  That's plenty for me, so the S3 should suffice 

I need to sort the chassis out before going big with the hp anyway.  It can barely contain stage 1, let alone 2!

I think you will probably be alright on standard intercooler to be honest. but obviously it will help keep things cooler. If your heading for no more than 330-350 id go witrh the cheapest option, either Ebay or S3 cooler.

[Paradox1]

[stuart-88]

I scrapped the bayonet fitting idea after a friend suggested to do what he did and tig weld on another pipe to the original turbo pipe. That way you can angle it whichever way is best as it's all pretty tight round that area!