Air to water cooler.... why don't i see a lot?

UFO

Veteran Member
Joined
Jul 31, 2007
Location
A mile high
TDI
2001 Beetle
In racing applications Water to air has an advantage so your FMIC does not get heat socked when your right behind someones bumper.

Only reason why I would go water to air is to preserve the stock front end on the golf. FMIC does not fit on a GOLF. Requires a lot of work, and it will never look stock.
I understand how it can be an advantage with tight spaces, but you still have to place your heat exchanger somewhere.

And you will still heat soak any place you would heat soak an air/air because the air/water still has to dump its heat to the air stream. Your racing scenario does not hold an advantage for air/water.
 

mattds

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Jun 3, 2009
Location
Toronto
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06 jetta
On a tuned (but stock turbo) TDI, is there an advantage of going with a large FMIC?
 

Bush Hopper

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97 Eurovan, 2001 Jetta and a few other
I understand how it can be an advantage with tight spaces, but you still have to place your heat exchanger somewhere.

And you will still heat soak any place you would heat soak an air/air because the air/water still has to dump its heat to the air stream. Your racing scenario does not hold an advantage for air/water.
Yes it does because the radiator that is cooling the water has a fan or two running the entire time. So air flow is provided, justifying my reasoning.

This issue could be resolved if someone installed 2 big fans on a FMIC. Actually most race teams will install big fans on the FMIC to solve the issue. You can only do this if you have the room. Water to air takes up a lot less space. Works good if someone wants a stealth stock looking golf with a upgraded side water to air cooler. Big FMIC does not look good on a golf. I know because I have done it. I have pictures somewhere. If I can find it I could email you them.
 
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UFO

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Location
A mile high
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2001 Beetle
Yes it does because the radiator that is cooling the water has a fan or two running the entire time. So air flow is provided, justifying my reasoning.

This issue could be resolved if someone installed 2 big fans on a FMIC. Actually most race teams will install big fans on the FMIC to solve the issue. You can only do this if you have the room. Water to air takes up a lot less space. Works good if someone wants a stealth stock looking golf with a upgraded side water to air cooler. Big FMIC does not look good on a golf. I know because I have done it. I have pictures somewhere. If I can find it I could email you them.
Installing fans is viable for either, and a FMIC is already taking advantage of the radiator fans. Where would you mount the heat exchanger/fan for an air/water/air on a Beetle anyway?
 

mk3pd

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Norway
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Passat Quattro :)
Oettinger modified hundreds of those late 80's Vanagons or T2 as we call them over here with the 1.6TD engine.

They also used similar coolers in the Golf 2 TD

I saw many of those back then,and they were actually quite effiecent.
Sure some of those are still around.

I wouldn't say it was a very complicated thing either.
Just the air to water cooler,electric water pump and a tiny radiator.

As long as the cooler can be found for a good price,i don't see any problem to find a motorcycle rad and a el water pump to use with this.....
 

pierre

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Joined
Nov 21, 2002
Location
Elizabethtown Pa.
TDI
2002 Golf gls
I am quite happy with my air water setup, Flying Kasper's points are correct. It was not cheep to install, it took alot of time but the end result is worth it. I agree that it is not for everyone.
I installed it in stages over a period of time. Because I like having projects for when it is not busy at work. Also I did not like any of the front mount golf pictures I have seen. I felt the few advantages of air water to be worth it. The air piping is way shorter and should make slightly less lag.
I like the option of turning the pump off when the mercury drops. It should help warm up times.
fwiw the new Ford diesels are using air water...
 

Bush Hopper

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Location
Thunder Bay and in the Bush
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97 Eurovan, 2001 Jetta and a few other
Installing fans is viable for either, and a FMIC is already taking advantage of the radiator fans. Where would you mount the heat exchanger/fan for an air/water/air on a Beetle anyway?
I never said anything about a beetle, but a golf.

I would have to think about where to mount it in a beetle. Mounting the actual core would be easy. Radiator would have to be mounted somewhere behind the bumper or under neath the car like a oil cooler.Proper planing and measurements are key. I do not think anyone on here, unless they have done it, can speak about any suggestion.

The OP, has to design his kit on his own, on where stuff will be mounted.

Battery relocation will be must back into the trunk. Big water res. will have to be located in the trunk.

Beetle is not an easy car to mod with stock bumpers. Anyone, who wants to race a Beetle actually installs the RS Body kit. Very few race with stock body panels.
 
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Farfromovin

Torque Addict
Joined
Apr 9, 2005
Location
Ventura, CA
TDI
03 Golf 2dr- PD150 6m
Kasper, I think you're throwing the Golf fitment issues a little out of proportion. Yes, it's a little tighter than MKIV Jetta's for some reason, but I have a 7" (I think) tall FMIC bolted under the crash bar. Grills fit, bumper fits spot on. Required a TON of trimming, no doubt, but it doesn't scream "non stock". I might put a 24x11x3 core under there too just to be difficult :)
 

Bush Hopper

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Joined
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Location
Thunder Bay and in the Bush
TDI
97 Eurovan, 2001 Jetta and a few other
Kasper, I think you're throwing the Golf fitment issues a little out of proportion. Yes, it's a little tighter than MKIV Jetta's for some reason, but I have a 7" (I think) tall FMIC bolted under the crash bar. Grills fit, bumper fits spot on. Required a TON of trimming, no doubt, but it doesn't scream "non stock". I might put a 24x11x3 core under there too just to be difficult :)
Show me a picture of your install with bumper off and on. I was not satisfied with a FMIC 2.5" thick 7" tall intercooler fitting. I was not willing to trim the crash bar to make it fit. Ton of triming does not represent bumper fitting spot on. I bet you trimmed so much of the bumper your grills did not want to stay in. I WAS not willing to trim anything on this bumper. Water to air was perfect solution. I am not blowing it out of proportions. You can not beat the stock look of this car with a FMIC.

http://img185.imageshack.us/i/22439347.jpg/
http://img836.imageshack.us/img836/220/98220772.jpg
http://img408.imageshack.us/i/buttomc.jpg/
http://img153.imageshack.us/i/closeupn.jpg/
http://img27.imageshack.us/i/frontdg.jpg/

If you guys do it, make sure you got a res!
 
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Alex22

Veteran Member
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Mar 8, 2009
Location
Western CT
TDI
2014 Jetta
I'll chime in here since I'm going to have to work on this air-water-air system whether I want to or not. This is the system that I am going to base this off of.

If you don't want to read through the whole thing I will give you the highlights.

List of materials:

- $150 Small Water to air IC
- $100 Bosch IC water pump
- $75 B&M 10x11 Heat exchanger
- $40 Various silicon couplers
- $30 Various fittings for oil and water lines
- $40 2” stainless charge piping
- $50 DEI gold foil

Total: $485

His IAT's are 40* lower than they were when the Jeep was naturally aspirated and it does not heat soak while climbing the mountain passes in Colorado. I would think that a 4 liter I6 gas engine would produce more heat then a TDI. To be fair, we have no data to say if a FMIC would have performed better on the Jeep.

I like the idea of using an air-water-air system because the intercooler can be under the hood and it is easier to run a 1 inch water hose up to a heat exchanger instead of wrestling some 2.5 inch air tubes, but that's just me and my 2 cents.
 

Bush Hopper

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Location
Thunder Bay and in the Bush
TDI
97 Eurovan, 2001 Jetta and a few other
Total: $485
I will say it one more last time. Dream on. Even if you do it, you wont ever admit to your budget overrun. Plus your missing parts in your kit because you failed to read this read. You under estimated the cost of tubing and other factors I will let you figure out on your own. Have fun wasting your money. Cheers.

P.S please post some of your pictures during your build. I will have my popcorn ready.
 
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sardo_67

Veteran Member
Joined
Feb 15, 2010
Location
CT
TDI
2015 Golf SEL 6spd
What are the extra costs? Tubing for this is pretty much just heavy duty garden hose, maybe a relay for the pump and fan. What kit did you use? I'm nit trying to argue I just want to know if I'm missing something
 

mk3pd

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Location
Norway
TDI
Passat Quattro :)
I will say it one more last time. Dream on. Even if you do it, you wont ever admit to your budget overrun. Plus your missing parts in your kit because you failed to read this read. You under estimated the cost of tubing and other factors I will let you figure out on your own. Have fun wasting your money. Cheers.

P.S please post some of your pictures during your build. I will have my popcorn ready.
Just because "you have done it" doesn't mean that other guys cant do it cheaper or different.
Geesh,sounds like you invented the air to water cooler.
 

StingrayRT

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Joined
Jul 20, 2005
Location
Slovakia
TDI
AUDI A6 2.7Tdi Avant Quattro
For AUDI 13 diesel I choose a internal heat exchanger with this new copper tube -





As you can see there is a new way to do a intercooler inside a 76mm tube and the best is to bend that tubes together with copper heat exchanger. Invisible high efficient water/air intercooler.
 

ChippedNotBroken

Veteran Member
Joined
Dec 29, 2004
Location
Pocono\'s, NYC
TDI
Jetta A4 1999.5 Green
Boy this thread is everything I love and hate about this site. Lotsa noise from disgruntled humbugs, and helpful thoughtful insights and advice - sometimes from the same poster!!!:eek:
 

dieseleux

Théoricien -TDIClub Contributor
Joined
Nov 14, 2006
Location
Pas assez loin pour vider ma tank!
TDI
Jetta TDI 02
For AUDI 13 diesel I choose a internal heat exchanger with this new copper tube -





As you can see there is a new way to do a intercooler inside a 76mm tube and the best is to bend that tubes together with copper heat exchanger. Invisible high efficient water/air intercooler.


You need device in water tube to make turbulence for better heat transfer between tube and water.
Beautifull artisanal work!




Dieseleux
 

Diesel_Benz

Banned
Joined
Jan 10, 2004
Location
Denver, Colorado
TDI
Mercedes
Dream on, another person who just never has done it before. Let me know how it goes for $400. NO WAY you will get all the materials for $400. Think like $1000 at least.
Clearly you've never done it either because you don't have a clue what you're saying.

http://www.superturbodiesel.com/std/forcedinductions-air-water-intercooler-t-292.html

Intercooler: $185 (and that was $85 more expensive than if I went with the more common design)
Pump: Free, already on the car.
Air couplers: $30
Hoses: $10
Radiator: Free, already on the car.
Intake manifold: $15 for the pipe
Total cost of my system: $238

Add $85 for a bosch water pump and $75 for a decent sized radiator (not a crappy tranny cooler) and wham bam thank you mam you're at exactly $400.

The ONLY way an A/W system could cost even remotely close to $1000 is if you pay somebody to build it for you.


Lalwlz, water is only good for short bursts of cooling.
That is mostly false information. The "short bursts" you're thinking of apply only to ice based coolers (used by drag racers/sled pullers). Radiator cooled systems are like air-air systems, there is no limit to their cooling time.
If you have a pump of sufficient flow and a radiator of sufficient heat rejection capacity there is no reason the water at the inlet should ever get more than 10*f above ambient, no matter how long you have the engine under boost.
I've crossed the Rocky Mountains several times (read, 10+ minutes at a time at 16psi boost) without stressing the system's heat absorbing capacity.

The only major modifications were relocating the intake manifold's inlet to the rear, converting the A/C condenser into a radiator and relocating the air filter.

Air-water is great for tight applications.
Thats exactly why I chose it. My car didn't come with any intercooler and mounting an air-air would have required body modifications or excessively long ducting. This didn't.


I will say it one more last time. Dream on. Even if you do it, you wont ever admit to your budget overrun. Plus your missing parts in your kit because you failed to read this read. You under estimated the cost of tubing and other factors I will let you figure out on your own. Have fun wasting your money. Cheers.
Please troll a different thread. You don't have the slightest understanding what you're talking about. Leave the discussion to people that have actual knowledge on the subject.

Invisible high efficient water/air intercooler.
Invisible, yes. High efficient, not even remotely with such low coil density, low surface area and low turbulence. Its better than nothing, but an effective intercooler its not.
 
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ChippedNotBroken

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Location
Pocono\'s, NYC
TDI
Jetta A4 1999.5 Green
:eek::eek::eek::eek:

The only major modifications were relocating the intake manifold's inlet to the rear, converting the A/C condenser into a radiator and relocating the air filter.
:eek::eek::eek::eek:

Gulp, I'd call that major.

Did I read this right and you had no air conditioning crossing the mid west?

Don't misunderstand, I love the idea of W/A, but no way my wife would ever ride in the car with me again if it had no air conditioning in the summer. Mmmmm, now that I think about it:eek:
 

Diesel_Benz

Banned
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Location
Denver, Colorado
TDI
Mercedes
Gulp, I'd call that major.
Not at all.

The A/C was already dead and I had no desire to revive it (I even yanked the entire HVAC system from under the dash for different plans that didn't pan out), converting to a radiator only required cutting off the fittings; 1 minute with a die grinder and 10 minutes to flush out all the mineral oil.
The air filter required 3 parts from Home Depot and was already done long ago.
The intake mouth took one night to fabricate; weld a plate over the old inlet, cut off the back, weld on a pipe and bend flat steel strips to support the cooler core.

Did I read this right and you had no air conditioning crossing the mid west?
Thats what windows are for. When its hot in Denver its rarely warmer than 70 above 8000ft, even in July. Mt. Evans, for example, the hottest temperature ever recorded is only 65*f. Its a great place to escape the heat of the foothills/plains and there is gobs to do in the summer.

Don't misunderstand, I love the idea of W/A, but no way my wife would ever ride in the car with me again if it had no air conditioning in the summer.
I never suggested that cannibalizing the A/C was the only or best option. I used the condenser because it was there, free and effective. I could easily improve cooling even further by replacing it with an actual designed-for-water radiator, but it works great as-is so why bother?

Small radiators are fairly easy to find, anywhere from an old $10 junkyard oil cooler to the $200 "specially designed" ripoffs from online stores. Many Audis have a small auxiliary radiator next to the intercooler that is good for this application.

Its far easier to route two 5/8" rubber hoses that don't care about bends than a pair of 2"-3" metal pipes that need to be straight as possible. :)
 

GoFaster

Moderator at Large
Joined
Jun 16, 1999
Location
Brampton, Ontario, Canada
TDI
2006 Jetta TDI
Diesel Benz, in all fairness, the "cost" of your proposed system for MOST people is no longer having an operational A/C system, and that's not a viable option in most cases.

Yes, you can make stuff like this cheaply using junkyard parts. You'll end up having to do more custom fabrication to make your random junkyard radiator fit the vehicle. If that's the direction you want to take, so be it!
 

Diesel_Benz

Banned
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Location
Denver, Colorado
TDI
Mercedes
Diesel Benz, in all fairness, the "cost" of your proposed system for MOST people is no longer having an operational A/C system, and that's not a viable option in most cases.
Let me repeat myself from my last post, just for you.
"I never suggested that cannibalizing the A/C was the only or best option."

Yes, you can make stuff like this cheaply using junkyard parts. You'll end up having to do more custom fabrication to make your random junkyard radiator fit the vehicle.
Its known as utilizing your resources. Some people only have eBay, some have junkyards and some farm the job out to a shop. Farming it out isn't fun or respectable, but however it gets done don't change how the system works.
 

ChippedNotBroken

Veteran Member
Joined
Dec 29, 2004
Location
Pocono\'s, NYC
TDI
Jetta A4 1999.5 Green
Whoa, I've been on your side till you called letting someone else do the work not respectable. Just in case you didn't think this though I will give you a run down of people that might still be respectable and pay someone else to do the work.

People who live in apartment buildings/Co-op's/Condo's/houses without garages. People who despite being proficient in their respective fields don't know a crescent wrench from a pair of pliers. People who do not have the time or the tools to do their own work. People who have access to true professionals who would do the job better and avoid the mistakes a novice would make that could be more expensive in the long run than paying for the work to be done.

As for not being fun? Some people have more fun planning a vacation than actually going on one. It is not without merit to do the homework, learn everything you can about something in order to make the best choices and let someone else have the "fun" of actually putting it together.

An example of this would be designing your own house. Or in this case figuring out the best way to cool your intake temps and hiring someone who knows what they are doing to figure out the best way to install it.

Sure any ol' doctor can do heart surgery, but wouldn't you want it done by a specialist?
Farming it out isn't fun or respectable, but however it gets done don't change how the system works.
 

DaveLinger

Veteran Member
Joined
Apr 9, 2010
Location
Morgantown, WV
TDI
2001 Golf TDI
Only reason why I would go water to air is to preserve the stock front end on the golf. FMIC does not fit on a GOLF. Requires a lot of work, and it will never look stock.
Uhh... I have a FMIC on my Mk4 Golf with a stock Euro bumper. The only visible "mod" to the bumper is that it doesn't have the three black plastic vent pieces. But those could be fitted with some cutting, and would probably be un-noticeable from stock, especially if I were to paint the intercooler.

...And then it would basically look stock and would not be much work. Just sayin.
 

Alex22

Veteran Member
Joined
Mar 8, 2009
Location
Western CT
TDI
2014 Jetta
Dude, obviously you do not know how to read. I just posted pictures of the build I did. I am assuming your blind.

I suggest you go troll around in another thread and stop giving people fake hope that they can actually build a proper water to air intercooler for $400.

Guys like you make me sick. Actually its obvious you have never done it.

Dude your a joke, if you think you got all the parts for $238! What kind of air couplers do you plan to use? 1 good air coupler will cost you $10, t-bolts, welding cost, polishing or ceramic coating, mounting hardware, bolts nutz, metal strips, hoses for the water, water radiator, fan, control unit, res, filler cap, zip ties, shipping, taxes, good Bosch water pump, wasted material when you made your noobish mistakes, what about electricity cost for your tig welder, water temp gauge, filler rods, argon gas to back purge it ($40 at least), cutting wheels, grinding wheels, brake cleaner, electricity to power your shop, and air compressor, wires, covers for your wires, solder, gas for your car when your running back and forth for missing parts, time electricity for your computer while your going to be doing research cuz you do not know what your doing, and many other? I have build 15 fmic, and 2 water to air setups. You have to buy bulk filler rod, 316 for 308 pipe. Tubing will cost you in $100 range plus shipping and taxes. Did you actually measure how many bends you need? Did you plan the route you want to the tubing to go, did you even take a look at the cost of tubing? 1x 180 degree bend will cost you $30 alone! No you didn't, so stfu.

Stop being a a jerk. I am trying to make you guys over budget for your projects. Quite a few setups on this forums are just ghetto and I do not care how cheap it was. Do it right, budget double of your estimate. double the $400. So you think your genius and you can predict everything that may go wrong on your build? No one can do that. Always some surprise.
The parts and costs in bold would be used in an air to air FMIC and the italicized parts are available to me for free/so cheap its not worth mentioning. I underlined parts that are just not necessary.
If you take a look at the Greasecar rally car's air to water setup it only needs 2 bends and one cast elbow to complete the pressurized air. Yes, it has a D24 intake but that setup could be made to work on a stock ALH intake manifold. Yes, I HAVE planned this out and have a rough materials list in my head.

Since a lot of people don't like to click links...

Yea, I know its not a finished system showing the water to air radiator.:p


Links to two other threads on other forums have showed that a air-water-air intercooler system can be built for well under your proposed $1500 or even $800, why is it so hard for you to believe it is possible. Just because you spent that much doesn't mean all of us have. How much have the FMIC's that you have built, highest and lowest price and how much did the air-water-air setups cost?


You should be ashamed of yourself, see what you started! :rolleyes:;):p
Sorry, I gave him the idea in the first place and yes, I am little ashamed;)


~Alex
 

Bush Hopper

Vendor , w/Business number
Joined
Dec 16, 2007
Location
Thunder Bay and in the Bush
TDI
97 Eurovan, 2001 Jetta and a few other
The issue is that some of you who have never build a water to air are speaking about it. Until you build it why are we even talking? I will believe when I see it.

everything I listed is a factor in the end result of the product. How can you Alex22 say that half the stuff I listed is free? Where? Are you going to take it from your employer? Steal it from your buddy? Shop lift it? I am assuming no. italicized items in my list are not free and they will come out of your pocket or someones pocket. Unless your so lucky everyone is throwing free stuff at you. The reality is buddy, I had to pay for it all. I used $60 or Argon to weld the pipes together. Purging is not cheap.

DaveLinger

Chopping up your bumper is far from stock looking. For me, the grills where a big thing. They had to stay.

Frankly, I am not sure why you guys are trying to convince me. Go do it, and learn on your own mistakes. Stop talking about theory, but show us results. Talk is cheap. I do not care. You guys will not convince me, your estimates are totally wrong. I manufactured inter cooler kits, If I ran a business like you guys, I would of lost on every sale. Instead I suggest you guys take my advice. I know most of you will not, that's your own problem. Over Budget every project. I would like to hear how many big turbo builds are 100% on budget. Never heard of one. Only way to be under budget is to over budget. I will give you guys one more last word of wisdom on in this thread.

Potential buyer went to look at a Ferrari, he asked the Ferrari salesman how much the insurance would cost. The salesman replied, you cant afford this car if your asking for the price of insurance.


Toys are expensive, cars are a money pit, tuning is a money pit. Tuning is only done for fun. If you believe you can do it for $238, or 400 and make it look professional, please feel free to do it. To those that have to purchase all bits and pieces, be cautious. Over budget!

 
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DaveLinger

Veteran Member
Joined
Apr 9, 2010
Location
Morgantown, WV
TDI
2001 Golf TDI
DaveLinger

Chopping up your bumper is far from stock looking. For me, the grills where a big thing. They had to stay.
Who's chopping up a bumper? I said you could trim the inside of the vent pieces if you want to keep them, in which case the fronts of the vents would be untouched and the bumper would look 100% stock.

For example here is my car. If my intercooler was painted dark and I install those vents, with the backs trimmed to fit, the end result is a piece of cake, and it will look stock. Not to mention you could run a smaller IC than mine.

Saying that it's "impossible" to run a stealth FMIC on a Golf is a weak excuse to run an atw system.
 

Bush Hopper

Vendor , w/Business number
Joined
Dec 16, 2007
Location
Thunder Bay and in the Bush
TDI
97 Eurovan, 2001 Jetta and a few other
http://img185.imageshack.us/img185/8416/22439347.jpg

Car makes 190 whp, but does not look it like!

vs

http://farm2.static.flickr.com/1293/4682835919_f92ffd2d29_z.jpg


Your bumper does not meet my requirements. I see your valence does not fit straight. It does not look stock, and it does not look good. At the time, my solution was water to air.

Compare Compare?

Anything smaller then 2.5" thick 27 long and 7 tall will cost a tone. 1" thick intercooler is the solution in my opinion. last time I checked, it cost $700 for the core that had similar cooling power. The rad support would need extensive work. But it would fit, with out trimming the bumper.
 
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ChippedNotBroken

Veteran Member
Joined
Dec 29, 2004
Location
Pocono\'s, NYC
TDI
Jetta A4 1999.5 Green
http://frozenboost.com/
why don't i see a lot of people on here or anyone for that matter running those?
i would guess it can reduce lag because there is less intake piping to fill up with air.
My guess is that most people are either unaware of the option (I know I wasn't until this thread) or think it is too complicated/expensive to implement.

As for the posters who have been whining about how expensive and difficult it is to implement this ...

Expensive is always relative, I know I have spent way more money than I could possibly justify to anyone but a few other fanatics here on the site. That said, I think keeping a TDI as Stealth as possible while at the same time improving performance is a worthy goal, and if you only do cheap upgrades that provide huge gains for the buck, then I guess this upgrade is not for you. But why make the rest of us listen to you whine about how much it costs without any understanding of the fact that not everyone values things the way you do.
 
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