so what intercooler now???

[Redliner]

noone, you are right, now we are gettng somewhere.
Also thanks Guy for the above info.
Ant, thanks for those graphs they do indeed highlight the pressure issue.
I think, and this is my opinion, that for my car...which will eventually go the fraken route, a THS intercooler would be best. Same design s a Seat one, but bigeer core ?
Views ?
Thanks

Taken from the THS website on core design Talking about the THS 2.0tfsi intercooler which has the same core as the THS Seat intercooler:

"The core
The THS TFSI cooler features a Bar and Plate core. Bar and Plate core offers similar cooling properties as tube and fin systems but has the added advantage of reducing pressure drop due to lower hydraulic internal restrictions. This means that the THS TFSI intercooler has a reduced pressure drop over the standard OEM cooler and S3 cooler.

Pressure drop
How does reducing pressure drop help?
On the 2.0TFSI engine the boost pressure is measured on the up-pipe after the intercooler. However the boost pressure here, or at the intake manifold will be less than that at the turbo outlet. This is because of the restriction of the intercooler and pipe work.
pressure drop
Example restrictive core
Intake manifold pressure: 25 psi
Restriction / Pressure drop: 6 psi
Turbo outlet the pressure: 31 psi

Reducing the pressure drop by means of a more efficient intercooler and pipe work requires the turbo to produce less boost pressure at its outlet whilst still maintaining the required boost pressure at the intake manifold.
pressure drop
Example free flow core
Intake manifold pressure: 25 psi
Restriction / Pressure drop: 3 psi
Turbo outlet the pressure: 28 psi

This has 2 distinct advantages:

Compressing air causes it to increase in temperature, the less it is compressed the colder it remains.
An intercooler which offers good cooling but with a high pressure drop due to restrictive core and excessive pipe work is less efficient than one with similar cooling but a less restriction.
The turbo is not working as hard to produce the same requested boost at the manifold. Prolonging the life of turbo.

[VWindahouse]

Nice info there. For me this part stands out in regards to the Forge core

An intercooler which offers good cooling but with a high pressure drop due to restrictive core and excessive pipe work is less efficient than one with similar cooling but a less restriction.

I don't think flow is an issue but it has imo inefficiently designed and somewhat excessive pipework. This has always been a suspicion of mine. My guess is they tested flow and thermal properties only but left pressure testing out by the looks of things.

[VWindahouse]

Check this out



See how the cold side pipework twists and bends to make it's way back up to the intake intake manifold.

As opposed to the SEAT (Leon used for picture purposes but pipework is the same route as the Polo)

[insanekiwi]

So where can I source the SEAT intakes these days? Sourcing seems to be the most difficult issue.

[nightphotographer]

Check this out



See how the cold side pipework twists and bends to make it's way back up to the intake intake manifold.

As opposed to the SEAT (Leon used for picture purposes but pipework is the same route as the Polo)

Pretty sure that's the Ibiza actually haha

[VWindahouse]

whoops

[nightphotographer]

I only noticed it because the Leon has inlet and outlet on different sides like the Golf - whereas the Ibiza, Polo and Fabia is all on the same side.

[kaanage]

I guess the original Forge FMIC suffers due to being designed for minimal installation change over the OE SMIC.

All the others seem so close in performance that any of them are a good option unless you are going to tune it for dyno wars.

The other thing about reduced pressure drop is that there should be less lag as I imagine the backpressure will delay the any boost increase a tiny bit.

[Lucas_R]

Has anyone tried one of these intercoolers on the Polos? I just installed their Mk5/Mk6 Golf intercooler (THS copy) last week and its brilliant. Fits perfectly and works like a charm.

Pics here

[vwthunder]

No a Golf 6 and a Polo are totally different, for starters its too big the exits are on opposite sides

I wish my polo was a Mk6 R lol

[Lucas_R]

No a Golf 6 and a Polo are totally different, for starters its too big the exits are on opposite sides

I wish my polo was a Mk6 R lol

No you have mis-understood me. They make quite a few different intercooler kits. They have a Polo specific version, a Golf specific version as well as quite a few others. See my links above.

[nightphotographer]

No you have mis-understood me. They make quite a few different intercooler kits. They have a Polo specific version, a Golf specific version as well as quite a few others. See my links above.

First links not working buddy - maybe that's why Troy got confused, only the link to your MK6 one works.

[vwthunder]

No you have mis-understood me. They make quite a few different intercooler kits. They have a Polo specific version, a Golf specific version as well as quite a few others. See my links above.

Oh cool

I will google it

[Lucas_R]

First links not working buddy - maybe that's why Troy got confused, only the link to your MK6 one works.

Oh cool

I will google it

Sorry guys - link fixed in my original post. But here it is again.

VW 02-05 JETTA Golf GTI MK4 1.8t Turbo BOLT-ON Side Mount Intercooler Kit | eBay

[Blitzen]

I have been looking at fitting one of these to my Polo GTI. The inlet and outlet pipes face the wrong way for the Polo, so some custom piping needs to be sorted out.