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Intercooler sizing.

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mk2polobloke Part of things Posts: 801	Intercooler sizing.mk2polobloke @mk2polobloke
	Jan 16, 2013 23:08:03 GMT Select Post Deselect Post Link to Post Back to Top
	I've got a really nicely made universal fit intercooler from Rally Design for my mk2 Polo project. I have managed to make it fit behind a heavily modified bumper but it is quite big. The core measures 500x240x65mm and the end tanks are quite large, overall it's fairly heavy too. I keep debating whether I should get the intercooler cut down to around 180mm high, it'll give me safer amount of ground clearance and make it a bit lighter. Will a reduction in volume help reduce lag? Engine is 1341cc with K03 turbo, will be boosting to circa 20+psi with water/meth injection. Any thoughts or shall I leave it as it is? Thanks in advance, Richard.


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mk2polobloke Part of things Posts: 801	Intercooler sizing.mk2polobloke @mk2polobloke
	Jan 19, 2013 17:15:14 GMT Select Post Deselect Post Link to Post Back to Top
	Anyone got any advice or information?


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chairchild Posted a lot Posts: 1,884	Intercooler sizing.chairchild @chairchild
	Jan 19, 2013 23:47:08 GMT Select Post Deselect Post Link to Post Back to Top
	Lag difference would be minimal between the two sizes, as most of the volume sounds like it's in the end tanks - but ground clearance is always a winner in my books! And 20psi on what I'm guessing is a petrol? Are you SURE you'll be able to run that safely? Turbo looks like it should just support that pressure, but it'll be on the surge line, if not quite a way into it. Plus I've not heard good things about going over 18psi on a k03. Set it up for 15psi for a "safe"maximum, and try 18psi on the rollers for a bit of fun (if it doesn't detonate like mad!)
	Aug 17, 2012 11:05:42 GMT waveman1500 said: You're like a crazy backyard genius!

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mk2polobloke Part of things Posts: 801	Intercooler sizing.mk2polobloke @mk2polobloke
	Jan 20, 2013 18:44:02 GMT Select Post Deselect Post Link to Post Back to Top
	Thanks for the reply chairchild. There are lots of people using this setup on Polo G40's converted to K03 turbo, it's fairly well documented now using off the shelf conversion parts. Many of these run over 20 psi without problem. The 1272cc engines are very strong and the 1341 bottom end is done using 77mm forged pistons. The standard ECU is fully mappable, 22psi and over 200BHP is attainable with good reliablity. However the G40 Polo has room at the front for a large FMIC. The one they use is slightly wider but thinner than the one I have. The end tanks aren't so well designed either, being quite squared off. My mk2 doesn't have the same room, hence me using a universal one. It's well designed but a bit deeper than I'd like.


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chairchild Posted a lot Posts: 1,884	Intercooler sizing.chairchild @chairchild
	Jan 20, 2013 21:24:57 GMT Select Post Deselect Post Link to Post Back to Top
	I still say, going from compressor maps - the turbo'son its limit Slap a bigger one on! Lol
	Aug 17, 2012 11:05:42 GMT waveman1500 said: You're like a crazy backyard genius!

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