Air to air intercooler in D pillar ideas please!

[dkoesyncro]

beautiful job! Please keep us posted. I want to see where this is going to be mounted.

[lloydy]

Now, while i would love to claim this work as my own...... it's not
All being carried out by the guy doing the bodywork on my van. I'll post pictures for sure as and when work is done, i'm really looking forward to seeing it fitted myself!
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16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.”

[Waldi]

[82pdtdi]

this is where i am putting my inter cooler still have to duct it in. i plan on adding a 911 turbo type scoop also.

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[POS]

"All my life's a circle"

Might take gander at this...

http://www.thesamba.com/vw/forum/viewtopic.php?t=394631&postdays=0&postorder=asc&start=0
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kombisutra wrote:

"This thead is about badgers, not hyenas.... get back on track ok?"

[lloydy]

i did see that thread, some good stuff on there..

here's a shot of roughly how it will be mounted

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16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.”

[goffoz]

Remember this little scoop,

Here are the splash shields, and tin around the fan.

Here's a view from the under side..this is what is behind the tin (tin is on the left)
The fan bracket is 1/8" steel and supports the IC (intercooler)
I used the D pillar pins and the stock power steering hose mounts to bolt up too...no extra holes
...looking rearward from the axle

And topside.position is good very solid ,lots of airflow

Still want to add a cover over the cooler to seal it too the D pillar.
...maybe vac formed plexi
I closed off the pillar behind the taillights

Here's aview thru the tailight opening
So 100% of the flow goes over the IC..but a litttle scoop on top of the IC would direct more air thru the IC at speed ..and protect the cooler from damage from careless tool use

[goffoz]

As requested..a pattern for the scoop.
All folds are in the same direction, long diagonal fold could be a gentle curve
notches on the bottom edge, are to clear the vent mounting tabs..a 1/4 " lip along here could suffice.
This pattern works for either side of the van.
Make a templete first, you may need to finese it a bit.

[Colorado Yeti]

Goffoz.........thanks for posting this!!

[danfromsyr]

quite a nice and clean install,
but a question what Fan thermostat switch are you using and what temperature would you want to set it at to come on?

I've been eyeing this reasonable one from Summit's fleabay store for under $30shipped
http://www.ebay.com/itm/Hayden-Fan-Switch-Thermost...mp;vxp=mtr
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[lloydy]

I got this one, and I'm going to set it up so it switches the fan on when IAT are 50c

http://www.carbuildersolutions.com/uk/adjustable-fan-controller-thermostat
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16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.”

[davevickery]

Could you just attach a normal limit switch to the case of the intercooler. I did that for a hot water tank. Just siliconed it to a place that had good conductivity of the water temp. Only cost a few bucks.
Something like this. http://www.alliedelec.com/search/productdetail.asp...MgodKHUAgw

[bluefirefly]

My fan is controled with the alternator blue wire, always on when the engine is running....
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86 Syncro Tintop G60
work in progress ...as always!

[goffoz]

[lloydy]

Well, i've now done around 2000 miles with the air/air intercooler. Here is some pics of it fitted

Vented out underneath

It works pretty well, slightly warmer than the water/air set up but no much. Around town @ 30mph-ish inlet temps are around the high 30's (degC) At 50-55mph on long sweeping up and down roads temps read about 45degC . Temps are the same give or take on the motorway at 60-65mph, but can go into the low 50's. Long hills on full boost fully laden it will creep to around 61DegC (highest i noted was 63)
I am happy with that, the peak temps are about the same as the water set up. I do think there is some to be gained by fitting scoop to the top of the D piller. I love that version posted above and would like to see it from a angle that shows how far out the scoop sticks out. I have my name down with a german company, who make one in plastic, but they are sold out at the moment.
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16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.”

[Waldi]

[lloydy]

Lucky man! Now, do you actually have four vans?..
He did say he was waiting on a order, then he'll remake. Did you notice a difference before/after with the scoops fitted?
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16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.”

[Waldi]

[goffoz]

Here you go, small production run has begun, still dialing in the folding dies

[Waldi]