De Ja Vu! Intercooler Blowout!

[Michael Pederson]

Audi must have given this some thought when it got around to the 92-97
UrS4/6's.  The OEM IC I'm looking at appears to have had the cast aluminum
end tanks welded to the core.

As a matter of curiosity:

1.  What IC core size are these (??) earlier tanks?  The UrS4/6 uses a core
@ 3.47" thick x 9" tall x 11" wide (surface exposure @ 99 Square Inches & a
volume of @ 343 cubic inches.)

2.  From those who have "blown" the ends off, any description or photo of
the nature of the interior (charge air) cooling duct works?

I've no idea what the UrS4/6's charge air channel's core interior looks
like, but I've seen "cut away" views of several different manufacture's
products that show anything from a single "smooth" charge air channel to
from 2 to 4 or 5 or more added internal extruded "fins" that project into,
and run parallel with the air flow to provide more "contact" area.  These
enhanced area cores seem to weigh as much a 1/2 to 1/3rd more, size for size
than what the stock OEM UrS4/6 Audi IC core appears to weigh.

Information seems pretty sketchy when it comes to trying to quantify the
relative merits of one design vs. another, although empirically I've seen a
Magazine article trying to draw comparisons between, I think it was a Toyota
OEM IC for I believe the Supra, and two competing aftermarket IC kits from
Greedy & A'pexx.  The testing was done on a rear wheel drive dyno and as I
recall the aftermarket kits did, at best, no better than the OEM unit, and
perhaps a little worse.  The articles caveat however was the "incredibly
good job the OEM was able to do with all its resources in fitting very good
ducting to and around the IC to assure the maximum use of what was there..."

Mik ep>

-----Original Message-----
From: quattro-admin at audifans.com [mailto:quattro-admin at audifans.com]On
Behalf Of Swann, Benjamin R. (BSWANN)
Sent: Monday, November 20, 2000 5:11 PM
To: '5kcstq at codenet.net'
Cc: 'quattro at audifans.com'
Subject: De Ja Vu! Intercooler Blowout!



<87 5kcstq 1.4...1.5...1.8...2.0...shift...BOOM!!! courtesy of aptly
named "schrapnell knobben".>

That's why you strap the IC first - of course I didn't wait either.  "We'll
just test this mod out and see what a little extra boost feels like."  Thank
goodness this usually happens only a block or two from the garage.

You can put the end caps back on.  Pry up all the tabs.  remove end cap and
seal.  Clean.  Use Permatex/Aviation/Marine Sealant - gooey black stuff
applied with a brush.  Apply liberally.

Carefully refit end cap.  Carefully hammer down the tabs - a little at a
time.  Then strap end together using two long (20" or so) hose clamps.  I
used rubber hose to cusion the straps when tightening. I also cross strapped
mine - 4 clamps total.

Now - how to keep the Michelin Mn hose from bursting, like mine did this
weekend while pulling three I5 engines in my trailer approaching triple
digits when someone cut me off.  The black cloth tape got me home.  The MM
hose was almost brand new.

I love this car - so stable even at high speed pulling a loaded trailer!

Ben
5KCSTQW ~ 2Bar Boost