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T4 : Battle Across Time (2010 to present)

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  • Found this in the garage roof space whilst looking for some stainless, 3 sections of 76mm pipe and some tailpipes.....

    Sent from my SM-G901F using Just T4s

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    • First fit this afternoon with the new intercooler. The OEM body work mountings will be used with some new brackets with the centres being almost identical at the top. There's clear line of sight for the 76mm inlet and 76mm outlet pipework. The silicon hoses need trimming and angling but so far so good. Might need to extend the MAP sensor cabling. Got a replacement slam panel to paint up once it's all bolted in and fitted....[emoji6]


      Looking at the pics again I'm thinking about trying to mount the IC over the top of the air filter and splitting a forced / cold air to it....[emoji848]

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      Last edited by Activ8; 29 June 2018, 12:45 AM.

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      • Do you know the flow rate of the intercooler, I'm wondering if my intercooler ought to be larger.

        It has surface area because it's long and thin which means the flow rate is low, yours has higher flow rate but less effective cooling

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        • I'm sure my IC calculator just uses width and depth. Need to look it up but Im sure this one was good for 280bhp. Think Im going to put in 2 seperate cold air feeds and pipework to the IC to keep the pressured pipes short and a large diameter.

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          • Ive never seen anyone post an Inlet manifold upgrade comparison for the AJT & ACV so here you go...



            From top to bottom
            AXG with 52mm ID inlet
            AHY with 63mm ID inlet
            Volvo with 54mm ID inlet

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            Last edited by Activ8; 27 June 2018, 12:42 PM.

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            • Originally posted by regcheeseman View Post
              Do you know the flow rate of the intercooler, I'm wondering if my intercooler ought to be larger.

              It has surface area because it's long and thin which means the flow rate is low, yours has higher flow rate but less effective cooling
              Looked up my calcs , these were based upon the book Maximum Boost, Designing, Testing & Installing Turbocharger Systems by Corky Bell.

              Intercooler information at www.bellintercoolers.com/ft-3085-faq.html

              Here are the stages and calculations for anyone interested in buying / installing or upgarding their IC;
              I've used 300bhp as an example.
              1.) Calculate Internal Flow Area, using
              a) turbo airflow rate (cfm - cubic feet / minute) or
              b) desired bhp (horse power)
              I'll use b) as most owners don't know their turbo cfm.

              So, nice and easy, just use 6 sq inches per 100bhp, so 300bhp x 6 /100 = 18 sq in
              Internal Flow Area = 18 sq in

              2.) Intercooler Sizing
              Most cores require 45% of their Internal Flow Area to be the Charge Air Face (the area of the “top” of the intercooler, not the front).* So calculate that to find the Area of the Charge Air Face:
              Area of the Charge Face (sq in) = Internal Flow Area / 0.45

              So, 18 x 0.45 = 40 in sq

              3.) Intercooler Length
              Divide the Charge Air Face Area by the depth of the IC (most are either 2 or 3 inches) to find the*width of our intercooler.

              So, 40 in sq / 3 = 13.33 in
              The front face of the IC needs to be 13.33 in

              4.) Pipework Diameter
              Air flows most efficiently between Mach 0.4 and 0.5 (440ft/s and 550ft/s).*
              Anything faster than that, and drag starts*to negatively affect the IC's flow.*
              You'll need the Turbo Airflow Rate (cfm) for your setup.
              For my Pipe Diameters I use an air velocity (ft/sec) of Mach 0.4.*

              Formula, (12 x Turbo Airflow Rate (cfm)) / (5 x 3.14159265359 x 440) x 2

              These are calculated figures and should be used as a guide only. Your setup may be different!
              At 5000rpm on a 2.5TDI at 25psi (2.72bar) with 150% Volumetric Efficiency the turbo airflow rate is 887 cubic feet / minute (cfm)
              At 5000rpm on a 2.5TDI at 19psi (2.3bar) with 150% Volumetric Efficiency the turbo airflow rate is 750 cubic feet / minute (cfm)

              So, ((12 x 887) / (5 x 3.14159265359 x 440)) x 2
              So, (10644 / 6.911) = 1.54 x 2 = 3.08 in diameter.

              Hope this helps?
              Based upon the book Maximum Boost, Designing, Testing & Installing Turbocharger Systems by Corky Bell.

              Sent from my SM-G901F using Just T4s
              Last edited by Activ8; 27 June 2018, 01:26 PM.

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              • Delivery this morning from the jungle - 63mm 135 degree silicon hose. ASH (same supplier) on eBay was advertised for £23 when I looked but currently discounted to £17.10! Amazon £12.39 incl next day delivery in the colour I wanted. Big saving for such parts....

                Even funnier is the item was £15.40 + delivery direct from their website.... have fun in the jungle!


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                Last edited by Activ8; 28 June 2018, 10:55 AM.

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                • Had a chat with K&N UK this morning about their cold air feed systems - there is no dedicated kit - really helpful guys but got the info I needed. Did a search locally and this afternoon collected this ....

                  Good to 350hp according to K&N.Had to order an adaptor - its basically a uniquely sized silicon pipe to connect the sealed filter system to my larger Volvo 80mm MAF housing.

                  Next I need to decide where to get the air from? Side or front or both?????

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                  Last edited by Activ8; 3 July 2018, 07:10 PM.

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                  • Back on to mocking up some brackets for the larger TMIC. On the To Do's are fouling the wiper arm mech with the 3" deep IC, fouling the bonnet latch , relocating or a new bonnet stay, relocate the power steering fluid feed, opening up the top air flow feeds to cover the larger IC.

                    Keeping Sydney off m'nuts.

                    Sent from my SM-G901F using Just T4s


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                    • Originally posted by Activ8 View Post
                      Had a chat with K&N UK this morning about their cold air feed systems - there is no dedicated kit - really helpful guys but got the info I needed. Did a search locally and this afternoon collected this ....

                      Good to 350hp according to K&N.Had to order an adaptor - its basically a uniquely sized silicon pipe to connect the sealed filter system to my larger Volvo 80mm MAF housing.

                      Next I need to decide where to get the air from? Side or front or both?????

                      Sent from my SM-G901F using Just T4s
                      You'd get a greater flow of air from a front feed, but less flies from a side feed

                      Sent from my vernee_M5 using Tapatalk

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                      • K&N recommend a front feed to pressurise the cone and air feed. I'll try both individually and log the results.

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                        • Shame you can't do a twin headlight setup a la projektzwo and remove the os inner headlight like on the escort cosworth rally cars.

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                          • The area (currently 50mm diameter for the headlight washer) is already there under the o/s headlight , the K&N feed is only 63mm in diameter so the plan is to open it up and modify the front panel.

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                            • Are you going to keep the hole square or make it round? Square looks just that bit different

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                              • Received the intake adaptor today . A quality bit of kit with fittings to suit from K&N UK. Hopefully will get 15 minutes this evening to get the cone and adaptor on....


                                Colin01332 is now back from France and popped over with an original 2.5tdi air intake box - never took in the design aspects before but looks like the angled intake trumpet can be removed - could possibly block it and feed a cold air intake into it? I wonder if there are different sized trumpets that could clip in?
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                                Last edited by Activ8; 4 July 2018, 04:54 PM.

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