Sleeps 4 at 120

Not done yet, but thought I'd ask for comments. I know it won't flow as good as if I fabbed some new end tanks, but it's gotta be better than the dual pass stock setup. Basically I took the tanks off and unleashed the Dremel on it. I plan on plugging the old inlet hole, and modifying the drivers side tank with the cut piece as in the pictures below.

Best thing about this is the only cost will be for new piping from the turbo.

Eh?

<img src="http://pictureposter.audiworld.com/43680/ic-1.jpg">
<img src="http://pictureposter.audiworld.com/43680/ic-2.jpg">
<img src="http://pictureposter.audiworld.com/43680/ic-3.jpg">
<img src="http://pictureposter.audiworld.com/43680/ic-4.jpg">

fusilier

huh?

teabagger

Just seal it really good and you should be fine. Post pics when you're done, I'm curious to see it.

Sleeps 4 at 120

You're the turbo man...think the air will be too turbulent in there?

fusilier

That looks like a plastic end cap.

Sleeps 4 at 120

This project is using the stock dual-pass intercooler as a base - got it from Adam Mowafy to do something like Tox's old conversion. But thought I'd try this uber-cheap route first.

Here you see one of the stock end tanks with the inlet and outlet. The inlet has been mostly cut off, and the divider in the center that would normally route the air to first 8 passages has been dremeled out. I am holding the end tank by the outlet where the Michelin Man hose attaches. The original inlet (on the right side of the pic) will be plugged.
<img src="http://pictureposter.audiworld.com/43680/ic-1.jpg">

This is the other end tank that normally just 'loops' the air to the top 8 passages of the intercooler on it's way to the outlet &amp; Michelin Man hose. The inlet tube that was cut off the other end tank, as I said above, is just sitting on the end tank in this pic. The plan is to use a hole bit to cut out a section so the inlet tube/flange will fit in there, and I will use high temp epoxy, JB Weld, or something like that to secure it.
<img src="http://pictureposter.audiworld.com/43680/ic-3.jpg">

And this is my plastic coated sanding bit. I used a cutoff wheel to get the major pieces out and then this bit to do the finer work.
<img src="http://pictureposter.audiworld.com/43680/ic-4.jpg">

When it's all said and done this will still fit in the stock location as all the mounting holes, etc, are still intact. I will have to get some new plumbing for the turbo outlet to the relocated inlet of the intercooler, but that's relatively easy.

fusilier

I understand what your doing by removing the dividing wall to get a single pass intercooler.

here's why I said "huh"
I've never seen aluminum cores with plastic end tanks. I suppose it should work, but if your boost pressure is say 14.7 psi (1 bar) over atm. then an end cap that measures 10x6 inches will have about 882 lbs of pressure trying to blow it apart.

Sleeps 4 at 120

That's why we strap 'em up with big metal straps

fusilier

5kt run lower boost than an Urquattro.
It will probably be okay for that application.

I'm not 100% behind the concept of plastic intercoolers. Plastic is much more of an insulator than a thermal conductor.

5000turboman

ya my intercooler's endcaps are plastic as well...and im running about 14 psi...its strapped up and i havent had any problems yet...