Large IC install/pluming

[S2central.net]

This is good work here by Bo... Pity there are no air temperature measurements to compare the stock intercooler with this big thang... That would also give Roger the smoking gun of evidence for Jamo as the temperature drop would explain the pressure drop (for the same flow of air exiting the turbo).

[s2_bo]

Ok good - ill get a few more made up then and will post some pics when they are done.

I have sorted the snub mount too so the new ones will be a straight replacement.

Cheers.
Bo

[Technogym]

@ bo: I would also be interested in a cm lik this! Looking forward for pics and prices! I am impressed over Your work!

Vegard

[Greg_S]

Keep me upto date on this, later in the year I may be interested once again

[s2_bo]

Cheers Jamo,

Still not a 100% on total costs for the crossmsmeber because the welding will be slightly different on these improved ones.

Mine cost about £60 - £70 all in.. but might have been less because i got some pipework welded at the time two and the guys didnt break up the bill for me.

Cheers,
Bo

[Jamo]

How much did a cross member cost to make up Bo? and how have you attached the Aux rad?

AFAIK Snub mount is in the same place as the cross members are interchangable on the ADU, ABY and 3B when members previous upgraded intercoolers to OEM ABY or ADU ones.

I have a V6 crossmember and the mount is in the correct place but probably best to get a confirmation from Doug / Martin

[s2_bo]

I have come up with a solution for the snub mount, leaving it at it original state. I will be attaching a bracket to the crossmember so that the mount is cupped Very similar to the bracket on the stock corssmember.

I am having 3 more crossmember made up for forum people and just want to make sure that the 3B sump mount is in the same place as the ABY one. Is this the case?

If not it will make things a bit more complicated.

Can someone please confirm this for me.

Thanks in advance.

Regards.
Bo


P.s. Ill have a total cost for the xmembers soon.

[Rusty]

Didn't Mark H use an S4 snub mount? I'm fairly sure a solutio is covered in one of the original threads. HTH

[Dpicariello]

The snub mount is to hold the engine down so it doesn't come up out of the bonnet when you drop the clutch, or go out through the IC when you hit the brakes

That little thing stops that from happening!
Better make sure I restrain the lil' ******!

[s2_bo]

The snub mount is to hold the engine down so it doesn't come up out of the bonnet when you drop the clutch, or go out through the IC when you hit the brakes I think I'd rather go for a CM that allows me to keep it.. Should be possible as others have done it. IIRC there are 2 different rubber bungs, a big one for cars with AC and a smaller one for cars without.

Thanks John,

Thats ok though, I haven't modified the Mount at all. At the moment it sits very tightly right under the crossmember so theres no chance of it lifting up. Theirs nothing stoping it puncture the IC though. Ill have to get a stopper bracket welded on to the front of the Crossmember to stop the snub busting in to the IC.

Thanks again for shedding some light.
Cheers.
Bo

[newsh]

The snub mount is to hold the engine down so it doesn't come up out of the bonnet when you drop the clutch, or go out through the IC when you hit the brakes I think I'd rather go for a CM that allows me to keep it.. Should be possible as others have done it. IIRC there are 2 different rubber bungs, a big one for cars with AC and a smaller one for cars without.

[Rusty]

Let us know what the damage on the XM was / will be when you know.

How are the drawings coming along?

[Briggsy]

well done s2 bo, my hat goes of to you. its reasuring to know that us boys with the oe front bumper can get soemthing that big behind it and still keep the aux rad.
good write up aswell!

[s2_bo]

The stainless pipe is 3mm thick? Thats pretty heavy. Can you get thinner stuff? 1.5 or 2mm should be plenty thick enough, I would think.

I'd like to order a crossmember if you're thinking of having some made

Yeah that's true John, The 3mm Stuff is quite weighty. - Like you said im sure 1.5mm would do but its a bit late now

Reg, the crossmember. Im just trying to source some more of that 40x40mm box section. Then ill get the welders to make a couple more. - Another member wants one too.


--

On a different note, I have a question about the Snub Mount. In order to get the Corssmember to fit i had to take the Rubber stopper off. Now leaving the Snub mount exposed. I presume this is ok. Please let me know if its not. Im not really sure what that thing is for anyway apart from holding the crank look tool..

Cheers guys.

[Faheemo]

To add my experiences, Ive recently purchased a WaterInjection kit to bring temps down and for some methanol aid.
I purchased a Nordskog air Temp aswell and tapped a sensor into my intake manifold.
To my utter amazement my car produced a max of 36deg Celsius whilst boosting hard in simulated drag mode !!
I am still using standard S2 inter cooler and test was done with water injection switched off. The ambient temp on the day was 24 deg Cel.
I did not believe the sensor and logged intake temp with vag com ... result similar temps.
So my conclusion .. a big effiecient turbo does not make lotsa heat to require a monster intercooler.
I will be changing mine , but mainly to help with the airflow...
BTW: water injection brought the temp down by 5-7 deg cel.

on another note: a friend of mine has a POLO GTi standard except for a chip modification. The intake temp on the car goes upto 90 deg Celsius...
Another Golf GTi I've measured was @ high 60's standard !!
Turbo very inefficient when boosting them high...