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OK, we're at phase two. My first thread was a lot of rather trivial messing around and testing / learning, now it's time to start getting serious.
I had the hose for my intercooler spray made up today at Enzed, at a measly $25 for a 300psi hose. The plan is to put this in and set it up with the smart spray controller made from a modified mixture meter from Jaycar. I've built the modded kit, and just need to mount it all and set it up. Having monitored the intercooler temps for several weeks now, I'm convinced of two things:
1) the stock intercooler does a tremendous job of handling normal driving temp spikes, with turbo outputs around 120 degrees only giving a several degree post intercooler rise at speed. It's a great heatsink for normal road use.
2) The time you REALLY need an intercooler spray is after a minute or two idling at the lights or in heavy traffic. The pre intercooler drops down towards 40-50 degrees on idle, whilst the output which is normally a few degrees above "ambient" starts to heat up towards this figure. After 2-3 minutes they are almost the same, and the intercooler output remains well over 40 degrees for several minutes of driving afterwards! Heatsoak at the lights is by far the biggest issue for the TDI, hence my spray is going to be geared towards this area. My smart controller is adjustable to turn the spray on at a certain intercooler temp, and I'm going to co trigger the radiator fans in conjunction with a pressure switch, so the fans only run when I'm not moving / moving slow.
This way the forward shooting mist will be drawn into the cooler at idle, and do it's best to help when it's most needed. There's links in my old thread for the coffee pump intercooler spray, and the smart controller, both from Autospeed.
My next area to attack is the inlet, and apart from keeping the stock MAF for now, which is a obvious restriction but necessary till a custom tune can be added, the entire lot is going to be replaced. Will take a few weeks to get right, but I've amassed all the bits and had my handy old man lathe a few bits up as well. He's an electronics engineer with a hot rod affliction to boot, which is about to start coming in very handy. Go Pa!
Then it's onto the exhaust, and the DPF bypass dump pipe is the go, and I'm at the stage of working out how to fool the O2 sensor, but it's looking very possible. Keep my mostly stock pipe and DPF for 95% normal driving, and have a secret weapon for the fanging.
Meantime I'm saving my butt off for a normal clutch to replace the dual mass, and a Peloquin or Quaife "LSD" to help the poor thing launch right.
Going to be a good "next" thread.
I had the hose for my intercooler spray made up today at Enzed, at a measly $25 for a 300psi hose. The plan is to put this in and set it up with the smart spray controller made from a modified mixture meter from Jaycar. I've built the modded kit, and just need to mount it all and set it up. Having monitored the intercooler temps for several weeks now, I'm convinced of two things:
1) the stock intercooler does a tremendous job of handling normal driving temp spikes, with turbo outputs around 120 degrees only giving a several degree post intercooler rise at speed. It's a great heatsink for normal road use.
2) The time you REALLY need an intercooler spray is after a minute or two idling at the lights or in heavy traffic. The pre intercooler drops down towards 40-50 degrees on idle, whilst the output which is normally a few degrees above "ambient" starts to heat up towards this figure. After 2-3 minutes they are almost the same, and the intercooler output remains well over 40 degrees for several minutes of driving afterwards! Heatsoak at the lights is by far the biggest issue for the TDI, hence my spray is going to be geared towards this area. My smart controller is adjustable to turn the spray on at a certain intercooler temp, and I'm going to co trigger the radiator fans in conjunction with a pressure switch, so the fans only run when I'm not moving / moving slow.
This way the forward shooting mist will be drawn into the cooler at idle, and do it's best to help when it's most needed. There's links in my old thread for the coffee pump intercooler spray, and the smart controller, both from Autospeed.
My next area to attack is the inlet, and apart from keeping the stock MAF for now, which is a obvious restriction but necessary till a custom tune can be added, the entire lot is going to be replaced. Will take a few weeks to get right, but I've amassed all the bits and had my handy old man lathe a few bits up as well. He's an electronics engineer with a hot rod affliction to boot, which is about to start coming in very handy. Go Pa!
Then it's onto the exhaust, and the DPF bypass dump pipe is the go, and I'm at the stage of working out how to fool the O2 sensor, but it's looking very possible. Keep my mostly stock pipe and DPF for 95% normal driving, and have a secret weapon for the fanging.
Meantime I'm saving my butt off for a normal clutch to replace the dual mass, and a Peloquin or Quaife "LSD" to help the poor thing launch right.
Going to be a good "next" thread.
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