Lets talk intercoolers

[Poverty]

Right lads, its not for the 2.0TFSI but instead for the 2.5 TFSI.

Now the stock cooler is piddly, and suffers from bad heat soak at stage 1.

Stock




Anyhow I have 3 upgrade options available.

The wagner, the pro alloy and the forge.

The wagner is good for 460hp apparently, which isnt enough so straight off my list.

That leaves the forge and the pro alloy. Both cost the same.

Pro Alloy - 9.6 litres volume








Forge 12.6 litres









Now at first it might seem a simple choice. The forge is much bigger so thats the one to go for right? However Ive been told that thicker cores are more likely to see a pressure drop across them which is something I really dont want. Then theres also core design and endtank design, flow rates etc. Basically im hoping some one on here will know what they are talking about and will give me a definitive answer as to which intercooler would be better.

My HP aim is between 500-550 hp.

[Hurdy]

The ED30 with the Twintercooler had more than 12.6 litres combined and didn't suffer from pressure drop.

Who is saying you will suffer from a pressure drop when you have a smaller volume I/C (although deeper) and a larger engine to push the flow through?

The calculation you really need is volume(cm³)/surface area (cm²) this will give you an idea of how effective the Intercooler should be at cooling the air flowing through it. The smaller the figure - the better the cooling capacity. However, you also need to know the internal diameters and how free-flowing the air is through the I/C and that's where it gets complicated. The deeper the I/C gets, the less effective the rear of the I/C becomes as it ends up heating the ambient outside air to the point where it is no longer efficient in cooling.

Imagine flowing boiling water through a tube and then there is another tube around it flowing cold air. The longer the pipe, the hotter the air will be at the other end. Eventually the air would get to almost the same temperature.

The only way to find out is to ask each of the I/C manufacturers why they have gone for the volumes they have and what power the I/C's are rated at.

[Poverty]

The ED30 with the Twintercooler had more than 12.6 litres combined and didn't suffer from pressure drop.

Who is saying you will suffer from a pressure drop when you have a smaller volume I/C (although deeper) and a larger engine to push the flow through?

The calculation you really need is volume(cm³)/surface area (cm²) this will give you an idea of how effective the Intercooler should be at cooling the air flowing through it. The smaller the figure - the better the cooling capacity. However, you also need to know the internal diameters and how free-flowing the air is through the I/C and that's where it gets complicated. The deeper the I/C gets, the less effective the rear of the I/C becomes as it ends up heating the ambient outside air to the point where it is no longer efficient in cooling.

Imagine flowing boiling water through a tube and then there is another tube around it flowing cold air. The longer the pipe, the hotter the air will be at the other end. Eventually the air would get to almost the same temperature.

The only way to find out is to ask each of the I/C manufacturers why they have gone for the volumes they have and what power the I/C's are rated at.

A very good place for me to start then, thanks hurdy.

The pro alloy was developed because some people where concerned about the forge unit, but the thing is we have no data to back up the concerns, but neither have we got any data on how the forge unit works on a mapped car.

I think, if the pro alloy core can cope with 525-550 hp it will be the one for me.

Jonny has the forge, but he got that before the pro alloy was developed. Ideally the best cooler is the THS one for the 2.0TFSI. A member has forced one in to his TTRS engine bay and his logs taken whilst hooning round the ring are just unbelieveably good. Trouble is he has had to modify the crash bar and some other bits to get it to fit.

Makes me wonder whether I could fit a S3 core without needing to mess with the vehicle integrity, and possibl combine it with a twintercooler