Date: Sat, 20 Mar 2004 20:31:48 -0800
Reply-To: David Marshall <vanagon@VOLKSWAGEN.ORG>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: David Marshall <vanagon@VOLKSWAGEN.ORG>
Subject: I need intercooler fan ideas!
Content-Type: text/plain; charset="iso-8859-1"
I spent the entire day getting my AHU TDI motor installed in my TriStar -
still have the electrical and the intake / intercooler system to complete.
The idea for the intercooler system is fairly straight forward. On the
driver side tail light opening, I am going to install a piece of 3mm
aluminium sheeting so that it seals that chamber off from the engine
compartment. Then I will cut a hole in this sheet metal and mount the
intercooler to it - making sure the intercooler is air tight to the
aluminium. The piping from the turbo to the intercooler and to the intake
manifold will be aluminium and I will reuse the rubber bits that came with
the factory tubing - installing a few more rubber piece to act as a buffer
for engine movement. The intercooler inputs will be pointing up with the
intercooler mounted as low as possible in the opening. I may have to be a
little creative to keep it all together when the engine is starting and
stopping as Diesels don't tend to stay in one place when doing this!
Installing the sensor in the pipe before the intercooler will be a bit of a
challenge too! Plumbing and installing the intercooler should be a few
hours work with a TIG welder.
What I want to do is mount behind the intercooler a high volume van that
won't mind getting wet. This fan will be wired into the 60C air temp sensor
that is present on the TDI motor - when the engine compartment is hotter
than 60C the fan will turn on - keeping the intercooler soaked in cool air
when driving and cooling off the engine compartment when you turn the motor
off after driving. Perhaps I might put a hose from this compartment to the
turbo to cool it off too. The trick is for me, finding a small enough fan
that will fit in the tail light compartment that will move a lot of air. I
am thinking of installing another 3mm aluminium plate horizontally at the
top of this opening / bottom of the 'tunnel' that goes to the outside vent.
This 2nd plate will again be sealed and the fan would be mounted to this
ensuring that air can only move forward and into the intercooler / engine
compartment.
Suggestions, comments and ideas please!
Thanks in advance!
David Marshall
Fast Forward Automotive Inc.
4356 Quesnel-Hixon Road
Quesnel BC Canada V2J 6Z3
http://www.fastforward.ca mailto:sales@fastforward.ca
Phone: (250) 992 7775 FAX: (250) 992 1160
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