S3 intercooler plastic end and metal end - Differences

[Sammy]

I just bought a brand new S3 intercooler but realised it has the plastic ends compared to the metal ends, From what i know this is the latest version but which one is more efficient in terms of cooling and what are the differences?

[the bruce]

Mk.V GTI - slim and plastic end tanks
S3 up to 2009 - thicker and alloy tanks
Mk.VI GTI + 2010 S3 + Mk.VI R - thicker and plastic end tanks

So VW & Audi used to save some money.
The plastic hybrid one isn't worth the hassle swapping ICs.

[Sammy]

Mk.V GTI - slim and plastic end tanks
S3 up to 2009 - thicker and alloy tanks
Mk.VI GTI + 2010 S3 + Mk.VI R - thicker and plastic end tanks

So VW & Audi used to save some money.
The plastic hybrid one isn't worth the hassle swapping ICs.

So are the plastic ones better then the metal end ones? How does the plastic ended intercoolers perform?

[Sammy]

Anyone? I need a answer for this ASAP please if anyone knows, if not plastic then il just get it sold

[scooba]

Just a guess but the Ali early versions are more expensive to manufacturer and are slightly better performance wise. Plastic is cheap and doesn't perform as well cost over ruling performance

[vRStu]

I think the Aluminium ones are still available.

[Sammy]

The thing is I already bought a intercooler with the plastic ends will that be enough for a k04 converted gti or will I need the metal ended intercooler? Apart from its not better then the metal one how good is it on its own?

[the bruce]

Mk.V GTI - slim and plastic end tanks
S3 up to 2009 - thicker and alloy tanks
Mk.VI GTI + 2010 S3 + Mk.VI R - thicker and plastic end tanks

So VW & Audi used to save some money.
The plastic hybrid one isn't worth the hassle swapping ICs.

So are the plastic ones better then the metal end ones? How does the plastic ended intercoolers perform?

Of course not. Alloy = more effective cooling. Get it sold! 

[ROH ECHT]

I had a standard GTI fmic and I switched to the early alloy ended S3. The S3 with alloy ends will cool better due to alloy ends plus it was nearly 15mm thicker core. I also added a forge twincooler but the S3 would've been sufficient.

[56OctyVRS]

I was thinking about the plastic v alloy debate. Is there any documented proof that the alloy is better than the plastic ended ic. I dont think the key issue is with the end caps but mainly with flow rates. Alloy will actually retain more heat than the plastic. The plastic used on cars is heat resistant and actually has better thermal properties than alloy. If you touch any plastic plug or loom on a car it will be warm. You touch any alloy part on a car and it will be a lot hotter than the plastic. Id be more concerned about if there is any flow rate difference between the two ic rather than which has what on the ends.

[Sammy]

I was thinking about the plastic v alloy debate. Is there any documented proof that the alloy is better than the plastic ended ic. I dont think the key issue is with the end caps but mainly with flow rates. Alloy will actually retain more heat than the plastic. The plastic used on cars is heat resistant and actually has better thermal properties than alloy. If you touch any plastic plug or loom on a car it will be warm. You touch any alloy part on a car and it will be a lot hotter than the plastic. Id be more concerned about if there is any flow rate difference between the two ic rather than which has what on the ends.

This is interesting, I have the plastic ended inter cooler just not sure if I should sell it and get alloy ended one, your argument about it being cooler makes a lot of sense, also knowing the golf r and the 2010 s3's started getting the plastic ones so maybe they are better?

[martziniuk]

As long as the core size is the same I can't see there being much difference tbh.

[the bruce]

Is there any documented proof that the alloy is better than the plastic ended ic.

I'm sure you'll find sufficient information if you try a Google search.

I dont think the key issue is with the end caps but mainly with flow rates.
......Id be more concerned about if there is any flow rate difference between the two ic rather than which has what on the ends.

If so remove the IC and install a proper hose. Best flow you can get. No cooling though.

Alloy will actually retain more heat than the plastic.

The most important thing is thermal conductivity. Alloy has a much better TC than any plastic.
That's why you don't find any radiator core made of plastic.

The plastic used on cars is heat resistant and actually has better thermal properties than alloy.

That's complete bullsh*t.

If you touch any plastic plug or loom on a car it will be warm. You touch any alloy part on a car and it will be a lot hotter than the plastic.

And that's why alloy is the (second) best (after copper) material to make radiators.

The only reason why Audi changed to plastic ends is cost savings. VAG use the same
IC on all 2.0 TSI/TFSIs. It's common knowledge the 'old' S3 IC works better though.

[Jussa]

Sammy, how much did you pay for the new intercooler?

[56OctyVRS]

I disagree bruce. The plastic is heat resistant else it would melt and deform. It is a hardned plastic which name i forget. I know why they use alloy but the end caps are not in the direct air flow so wouldnt really aid in the cooling of the charge air. I was after back to back tests comparing the old s3 ic to the new ic. End caps dont mean a great deal unless by design they impede the flow of charged air. If the cores are the same size and the same internal design then they should have the same cooling properties. The newer cars dont have any issues when tuned with the ic with plastic ends.