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Side Mount Intercooler Query


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Almost at the stage of rebuilding the VRs after a few alterations, and after my bottom intercooler hose blew off before Christmas was looking at putting on a diy bottom hose, as the only cost difference is a 90° silicone bend and a 90° metal pipe over making up a replacement bottom hose itself. The bulk of the cost is in the bayonet fittings, circa 50 of our pounds sterling. So I thought about replacing the actual intercooler ends, and discovered that the PD100 intercooler and possibly the Ibiza one, don't have those stupid bayonet fittings, just swaged ends.

Anyone know if the pd100 intercooler has the same capacity as the VRs one?

There are a couple of threads on the site I found asking similar questions but just dead end without actually giving the outcome so I couldn't find the answer. If it has the same capacity, then I think switching intercoolers, and then making the replacement pipework will result in removing 6 of the bayonet couplings from the boost system, and if you have an egr delete too, then that would remove all but the one on the turbo end of the pipework. At the moment I think there are 8 in standard form, replacing the smic with a pd100 one would leave you with 2 if you are in stock form and 1 if you have an egr delete too. Removing most of the weak points.

Cost wise I reckon about 50 quid for a replacement smic at most, then 50 for 2 new bayonet couplings, then about 75 quid for 4 silicone bends and 2 alloy/ss bends. I know this is then getting mighty close to a complete upgraded smic and hard pipes from darkside (£250), but budget constraints and 'i did that' satisfaction might be worth it to some.

Cheers

Lennie

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Can't say for sure but my PD100 (remapped to 154) suffers from heat soak if ragged/ on track.

I was going to look into a vRS intercooler but forgot about it lol

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I just had a look at vagpart.com and the intercooler looks like the same one. The only difference in the part number is one is A and the other is E.

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  • 1 month later...

Ok folks sorry for dragging this back up, but I am still investigating cheaper ways to achieve lower temps without spending a fortune on a forge front mount or chopping up my crash bar and this is my theory which I am looking for opinions on. I know it's still a wee bit more expensive than I was after but I was hoping for some technical reasons on why it wouldn't work if anyone can think of any. My aim is to do away with as many of those stupid bayonet couplings as possible and give myself a bit of leeway temp wise when it comes to possibly sticking a stage one remap on it..

Basically my theory is to install two 140mm 2.25" inlet/outlet darkside front mounts attached to the bumper, one top and one underneath behind each grill and loop one into the other like a twin pass. The problem then being the lack of map sensor on those so then I was thinking of removing the existing intercooler and replacing with an aftermarket pd75/100 intercooler which uses Mikalor clamps rather than bayonet couplings.

I am thinking this will have the dual purpose of extra cooling and a built in map sensor housing. Run silicon/hard pipes from the turbo to the inlet on the top front mount, join top and bottom on the offside, run the bottom front mount to the bottom of the pd100 sidemount, then run from top of the side mount to the egr.

I am thinking this will do away with all but two of the bayonet couplings(turbo and egr), require no cutting of the crash bar, no requirement for a wide mouth, still have a regular number plate,and still give me a good base for later. The three intercoolers will cost about 180 plus pipes and hoses.

Technically are there any problems with this, such as increased lag and the like? Feel free to shoot me down in flames.

Thanks

Lennie

Sent from my Hudl 2 using Tapatalk

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You can get a seat sport front mount for around £100, and make own pipework via ash silicone.com. You could even buy a used front mount and clean it all out prob around £50 if on a real tight budget. I recon your going to spend more on your alternate method. You can get a ibiza crash bar that is direct fit and require no cutting, these often are on ebay for £20, you can then sell you Fabia one again for £20 then its free. Also sell on your side mount and pipe work, people buy these to convert back to standard to sell. :)

Edited by FromTheDarkness
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Cheers mate, I had thought of that, but got conflicting reports of whether the crash bar needed to be cut or not with the Seat Sport, then I thought of fitting an Ibiza crash bar, but wasn't sure if it was a straight fit for everything. I assumed the crash bar would fit, but wasn't sure if it was shaped different so would the bumper then fit back on.

Then I thought bugger it, time to get inventive [emoji12]. Couldn't find any pics around of anyone who had actually fitted both to see if it went swimmingly.

Lennie

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As far as I'm aware the only cutting needed on the Ibiza crash bar is two lugs at either end so that it sits flush once the bumper goes back on.

You alternate method sounds like a lot of hassle if I'm honest. Especially since you have dozens of people to ask who have done the SS style conversion, as well as a pictorial guide.

As Darkness said - pick yourself a second hand Seat sport cooler from EBay, then either go down the Ash silicone route or gamble on a Chinese made hard pipe kit from EBay, which have got fairly good reviews recently...

Jrjg

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As far as I'm aware the only cutting needed on the Ibiza crash bar is two lugs at either end so that it sits flush once the bumper goes back on.

You alternate method sounds like a lot of hassle if I'm honest. Especially since you have dozens of people to ask who have done the SS style conversion, as well as a pictorial guide.

As Darkness said - pick yourself a second hand Seat sport cooler from EBay, then either go down the Ash silicone route or gamble on a Chinese made hard pipe kit from EBay, which have got fairly good reviews recently...

Jrjg

Cheers for that. I don't have a problem with the Seat Sport intercooler itself, although I have heard poor reliability issues on higher power, but I'm more into cornering myself rather than outright power tbh, so that isn't a concern. The only issue I have with it is cutting the crash bar, but provided the locator lugs are all that need removed and the rigidity is the same then the Ibiza bar would be the preferred option......Actually the preferred option would be for someone to do an uprated sidemount without the poxy couplings, but hey-ho, we can't always have our druthers [emoji2]

Lennie

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Cheers for that. I don't have a problem with the Seat Sport intercooler itself, although I have heard poor reliability issues on higher power, but I'm more into cornering myself rather than outright power tbh, so that isn't a concern. The only issue I have with it is cutting the crash bar, but provided the locator lugs are all that need removed and the rigidity is the same then the Ibiza bar would be the preferred option......Actually the preferred option would be for someone to do an uprated sidemount without the poxy couplings, but hey-ho, we can't always have our druthers [emoji2]

Lennie

Sent from my Hudl 2 using Tapatalk

I see. I fitted the THS seat sport style inter cooler which is supposedly the thickest/deepest' one. All I had to cut off the crash bar was a slither, and I mean just a slither, from the top. I have a picture of how much was removed somewhere, but it was four/five inches long and perhaps an inch wide, or therefore bouts.

JRJG

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I should also mention - the amount you will need to trim off the slam panel, bumper and crash bar will all depend on where the cooler sits, I imagine there is a slight range it could sit in, for example when I inspected the slam panel which was supplied with the cooler - the previous owner had cut away at some of the near side. Which once we had put everything into place was totally unnecessary as the cooler was nowhere near touching the offside, also the boost pipes entered and exited on the near side. The only reason I could fathom is perhaps when he had fit it, the cooler was positioned slightly differently. :/

It is a bit of a trial and error scenario, line it up, chalk what is fouling, cut it off, line it up, chalk what is fouling, etc etc.

JRJG

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