[Vwdiesel] intercooler ?'s

[LBaird119 at aol.com]

>  I'm thinking the loss of efficiency for the Audi
>  cooler, compared to the Volvo cooler, would be made up for in the much
>  shorter plumbing connections, and decreased turbo lag.

  The Audi cooler is pretty efficient.  Jake was pulling around 200 F off of
his TD Rabbit with one.  The length of plumbing contributing to turbo lag
seems to be more myth than fact.  Most turbo lag comes from too large
a turbo for the engine.  Long tubing just makes for a little more buffer so
transitions would be smoother rather than slower.  Both are most likely
unnoticeable.  The only catch with the Audi intercooler is that the bottom
opening points pretty heavily downward.
  Plumbing should be fairly easy to weld together with prefab bends and
some straight.  Could go with mandrel bends for a nice smooth look and
flow.  A muffler shop should be able to bend anything you want, in single
pieces, if you don't mind the standard bends.  Of course that will be steel
instead of aluminum.  Maybe you could find some copper tubing?  That'd
transfer a little more heat than steel!
  Re-clocking the turbo is easy.  Just loosen the ~6 bolts holding the
compressor housing to the center section and turn.  It will likely stick
though.  If it's a KKK then it uses an o-ring and you can pop it off, oil
the seal, and slip it back on oriented as you want.  Garretts use a thin
gasket and it's likely to really stick and a chance it will tear when
separating.  Of course you should be able to get a new one but I think
all Volvos use the KKK anyway.
  I remember Dave Puleo got 45 mpg on his maiden voyage with his
245 Volvo, 4 door, sedan with a standard!  I think he did a little ceramic
coating and used the thickest head gasket.  He upped the fuel and boost
some too, as well as big exhaust.  I need to find him. He still owes me
6 new injector nozzles back!
     Loren