[s-cars] Labor Estimates for RS2 Conversion

[mlp]

Cody -

As far as I know, there is no "RS2" intercooler for the UrS4/6's.  Different body, different plumbing requirements, I think.

Second, I don't know that anyone has determined for "sure" just exactly how much additional air & or efficiency the Audi OEM RS2 piece in fact offers, if any, over the OEM UrS4/6 intercooler ~even on something like an Apples to Oranges comparison basis.  As one faction of Italians (the ones from the North, I think) is often overheard arguing with the Italian Stallions from the South, "Hey, size isn't everything."

Someone, somewhere in the past has probably posted the "gross" physical core dimensions for the RS2 (i.e., core height, width & thickness.)  Maybe even some of the "net" internal flow features &/or capacity (core construction, area open to charge air passage, characteristics of charge air flow channels (open, moderately choked with turbulators, hapersized turbulatored, etc.)

FWIW, your stock UrS4 core is, roughly,

-	3.75" thick by 9" tall by 11.5" long

-	That works out to a "gross" charge air face area of @ 33.75 inch^2 (9x3.75) of which typically, @ 1/3rd is actually open or available for use (see below)

-	A cool air entry face of @ 104 inch^2 (11.5 x 9)

-	Inside that box are 15 rows of two "tubes" each in which the pressurized charge air is cooled.  IMO only, those row are let's say "moderately" turbulated.  No science or even broad experience behind the "IMO", other than I've seen both cores in the buff, and I'd say "moderately" mostly by comparison to the Hapersized units construction, which looks to me like its got a fair number extra little aluminum corrugations stuffed in its channels.  I suppose I ought to get a "Finns" per inch count, but I hate to bring the Northern Europeans into something like this when there are already Italians involve.

-	In the more speculative "higher" math area, I calculate (roughly) that each tube in the stock IC offers about a 7mm (0.275") tall by 38 to 39mm (say 1.525") opening for the intake air to work its way through to the pistons ~> say an area of @ 12.5 to 13 inches^2 for the charge to enter, run through, cool off and then get collected up by the end tank and funneled on its way to your throttle body via a 2.1" ID outlet (that is if I've correctly read my old notes on this.  Somewhere I wrote down the IC Inlet is @ 2.75"OD/2.45" ID, and the outlet @ 2.34"OD/2.09" ID.)

-	So, if I've not got any numbers scrambled, or screwed up any of my multiplication etc., you'll have your intake air "exiting" from @ 12.5 to 13 square inches of IC charge air tube in to the end tank which then squeezes that cooled air back down and substantially speeds it back up to exit the end tank via about a @ 3.4 square inch IC to throttle body feed tube.

Before you jump on an RS2 solution, I think you need to find out in what areas, if any does the RS2 intercooler improve on any of the above.  FWIW, in my opinion, the stock IC seems to be a pretty good unit.  I'm thinking Hans und Fritz at the factory did a difficult to improve upon job with the design, fabrication and set up of the stock IC end tanks etc.

HTH
mlp


~-----Original Message-----
~From: s-car-list-admin at audifans.com
~[mailto:s-car-list-admin at audifans.com]On Behalf Of Cody Payne
~Sent: Tuesday, August 06, 2002 8:04 PM
~To: s-car-list at audifans.com
~Subject: [s-cars] Labor Estimates for RS2 Conversion
~
~
~Gents,
~     Need labor estimates for RS2 Conversion?
~
~- RS2 or Garrett K26/T04 Turbo - Med Hard
~- RS2 Injectors - Easy
~- RS2 MAF - Easy
~- Exhaust Cam - Med
~- RS2 Exhaust Manifold - Med Hard
~- Oil/Coolant Lines to Turbo- Med Hard
~- RS2 Fuel Pressure Regulator- ??
~

As the Northern Italians say to defeat the Southern "size is everything" crowd,
" - IC end tanks to Hose to TB,... VERY, very Hard."  :-)

~
~
~I figure around 10 or less hours done by a professional?
~
~Also how important is upgrading the Intercooler with the RS2
~conversion?  Is the RS2 Intercooler bolt-on?  Or just better to go
~with 3rd Party like Hap's TEC?
~
~
~
~Thx
~
~cp
~
~_______________________________________________
~S-CAR-List mailing list
~S-CAR-List at audifans.com
~http://www.audifans.com/mailman/listinfo/s-car-list
~
~