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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!
Comments: To: Mailing list - Turbovans <turbovans@yahoogroups.com>,
          Mailing List - TDI-conversion <TDI-conversion@yahoogroups.com>
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

- Vanagon Accessories and Engine Conversions - Vanagon, Transporter and Iltis Sales and Importation - European Lighting for most Volkswagen models

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