SeatSport Intercooler ordered - need help with parts

[Paazuzu]

So I've taken Gav's advice from the last Lakeside meet and have decided to go straight to Stage 2 CC tune, rather than stuffing around with Stage 1. Getting a dump pipe sorted soon and in the meantime have ordered the SeatSport intercooler from Darkside in the UK.

Getting my head around the parts required is giving me a bit of a headache, but following Redliners thread has been super helpful:
http://www.vwwatercooled.com.au/forums/f127/polo-ths-intercooler-install-part-number-thread-76802.html

Before I throw any more money at Ebay, I'm hoping someone can help confirm that I have the right parts ordered, and also what I'm missing?

So far I have ordered (as per the list of ebay links):

2 x Alloy Bend 90 Degree L Elbow 51mm 2" Silicone Hose Tube
1 x 51mm 2" Diameter Alloy Bend Elbow 45° Degree Aluminium
2 x 60mm to 51mm SILICONE STRAIGHT REDUCER HOSE BLACK
1 x 51mm 2" SILICONE HOSE 1 METRE STRAIGHT PIPE BLACK 1M


And I think I still need:


1 x C 51 straight coupler
1 x 51 cut straight length x 335 mm long
1 x A45-51 alloy tube
1 x A90 -51 alloy tube
1 x A90 – 51 alloy tube with map sensor
All hose clamps - how many in total??
Map sensor screws - or just the map sensor flange kit?
Plus cnc machines alloy couplers - not sure where to get these.


As you can probably tell I'm a bit confused! I'm guessing the map sensor flange kit needs to be welded on to one of the alloy tubes.

This is my first intercooler install so trying to get it right. Any help that anyone can provide is much appreciated!

Cheers
Dan

[h100vw]

So I've taken Gav's advice from the last Lakeside meet and have decided to go straight to Stage 2 CC tune, rather than stuffing around with Stage 1. Getting a dump pipe sorted soon and in the meantime have ordered the SeatSport intercooler from Darkside in the UK.

Getting my head around the parts required is giving me a bit of a headache, but following Redliners thread has been super helpful:
http://www.vwwatercooled.com.au/forums/f127/polo-ths-intercooler-install-part-number-thread-76802.html

Before I throw any more money at Ebay, I'm hoping someone can help confirm that I have the right parts ordered, and also what I'm missing?

So far I have ordered (as per the list of ebay links):

2 x Alloy Bend 90 Degree L Elbow 51mm 2" Silicone Hose Tube
1 x 51mm 2" Diameter Alloy Bend Elbow 45° Degree Aluminium
2 x 60mm to 51mm SILICONE STRAIGHT REDUCER HOSE BLACK
1 x 51mm 2" SILICONE HOSE 1 METRE STRAIGHT PIPE BLACK 1M


And I think I still need:


1 x C 51 straight coupler
1 x 51 cut straight length x 335 mm long
1 x A45-51 alloy tube
1 x A90 -51 alloy tube
1 x A90 – 51 alloy tube with map sensor
All hose clamps - how many in total??
Map sensor screws - or just the map sensor flange kit?
Plus cnc machines alloy couplers - not sure where to get these.


As you can probably tell I'm a bit confused! I'm guessing the map sensor flange kit needs to be welded on to one of the alloy tubes.

This is my first intercooler install so trying to get it right. Any help that anyone can provide is much appreciated!

Cheers
Dan

Dan, first time saver for you is a MAP sensor pipe for $90 already done.

You need 2 big 60mm clips and about 8 that will do 50mm.

It's so long since I made up my last kit I forget.

I'd wait until the stuff you have ordered arrives and mock it up on the floor and see whats missing. I have some 10cm lengths of 51mm silicon pipes and a 45 degree 51mm silicon and a 90 degree aluminium 51mm bend.

With my spares I am sure we could cover most bases.

Cheers

Gavin

[Paazuzu]

Dan, first time saver for you is a MAP sensor pipe for $90 already done.

You need 2 big 60mm clips and about 8 that will do 50mm.

It's so long since I made up my last kit I forget.

I'd wait until the stuff you have ordered arrives and mock it up on the floor and see whats missing. I have some 10cm lengths of 51mm silicon pipes and a 45 degree 51mm silicon and a 90 degree aluminium 51mm bend.

With my spares I am sure we could cover most bases.

Cheers

Gavin

Thanks for jumping in Gav. I appreciate your advice (and help!). Are you still offering the map sensor pipes? If so - put me down for 1! I'll order the clamps and then will do a mock up on the floor (good call mate). We'll see what's left once it all arrives.

Fun times ahead :cool:

[seangti]

If you PM me your email address I'll see if I still have the receipt from when I ordered all my guy. I think I had everything needed.

[h100vw]

Thanks for jumping in Gav. I appreciate your advice (and help!). Are you still offering the map sensor pipes? If so - put me down for 1! I'll order the clamps and then will do a mock up on the floor (good call mate). We'll see what's left once it all arrives.

Fun times ahead :cool:

I'll put your name on one Dan.

Gavin

[Paazuzu]

If you PM me your email address I'll see if I still have the receipt from when I ordered all my guy. I think I had everything needed.

Thanks Sean. PM sent.

[rgvlee]

So I've taken Gav's advice from the last Lakeside meet and have decided to go straight to Stage 2 CC tune, rather than stuffing around with Stage 1.

I've never driven a stage 1 polo before but considering the few mods required to go stage 2 it's a no brainer.

This morning with 9C intake air temps I had my highest MAF numbers yet, 178g/s, that's 30% more airflow than stock (120) on a CC stage 2.

[Paazuzu]

I'll put your name on one Dan.

Gavin

Thanks Gav - can pickup from you or whatever is easiest.

[Paazuzu]

You need 2 big 60mm clips and about 8 that will do 50mm.



Any recommendations on clips? The Mikalor ones look ok.

I was thinking of grabbing 8 of the 47mm - 51mm sized ones; and 2 of the 59mm - 63mm sizes. Hopefully they are the right size.

Having a couple of spares might be a good idea - after what happened to Sean's.

[Paazuzu]

I've never driven a stage 1 polo before but considering the few mods required to go stage 2 it's a no brainer.

This morning with 9C intake air temps I had my highest MAF numbers yet, 178g/s, that's 30% more airflow than stock (120) on a CC stage 2.

Gotta love winter!

[rgvlee]

Always handy to have a couple of extra clips, I grabbed a couple when I did mine and ended up using them when I needed to replace a couple of other IC pipe clips.

I used a g clamp to remove the stock clamps, worked out a nice cheap safe way to remove them... if you don't have the tool.

[h100vw]

Thanks Gav - can pickup from you or whatever is easiest.

Yeah, that's ok by me. I am off to the UK next tuesday though, so bear that in mind.

Also, just get Jubilee clips, stainless ones if you like shiny. As long as the inside of the silicon and the outside of the hard pipes is clean the pipes won't blow off.

Gavin

[Paazuzu]

I used a g clamp to remove the stock clamps, worked out a nice cheap safe way to remove them... if you don't have the tool.

Smart thinking - I've got one lying around somewhere!

[Paazuzu]

Yeah, that's ok by me. I am off to the UK next tuesday though, so bear that in mind.

Also, just get Jubilee clips, stainless ones if you like shiny. As long as the inside of the silicon and the outside of the hard pipes is clean the pipes won't blow off.

Gavin

Ok cool - I'll PM you and we can organise something that suits you. Will check out the jubilee clips too - not fussed about shiny either ;)

[Bora Sport]

How long are you away Gav?

[h100vw]

How long are you away Gav? July 18th :P

[Paazuzu]

Grabbed the MAP pipe off Gav today - so just waiting for all the other bits to arrive.

Kudos to Darkside - intercooler arrived 3 days after ordering from the UK!

[Paazuzu]

Alrighty all the parts are here and I finally have time to install tomorrow.

Although, the SeatSport bracket kit didn't come with any bolts (I know that they use some of the existing bolts but there's a couple either side of the cooler). I think I still need 4 additional bolts by the looks of things. The holes seem to be about 6mm in size. Will M6 bolts and washers do the trick?

[rgvlee]

They supplied bolts with my kit from darkside...

[Paazuzu]

They supplied bolts with my kit from darkside...

Just found them buried in the packing materials :facepalm:

Whoops.

[Paazuzu]

Got the sucker in but bar won't fit - will need to keep on cutting (tomorrow - as I'm buggered now and there's no light!).

11013

[rgvlee]

I managed to fit mine without removing the front bar.

When you say more cutting,you don't mean the front bar itself? As you don't need to.

[Paazuzu]

When I say bar I mean the front spoiler.

Some of the plastic around the grill and drivers side fog light is still a bit tight. How did you manage to fit it without removing the front bar?

[rgvlee]

Yes a fair bit needs to come out of the front bumper, grill and fog light surround.

It wasn't too difficult. For one of the mounts I had to cut a little bit more out of the radiator surround to get the bracket in.

[rollehgoo]

Looks the goods! Super keen to do mine asap now.
How hard was it?

[h100vw]

Looks the goods! Super keen to do mine asap now.
How hard was it?

Pretty much normal handtools for fitting, except for some torx bits.. Google Forge's installation guide.

Gavin

[h100vw]

Got the sucker in but bar won't fit - will need to keep on cutting (tomorrow - as I'm buggered now and there's no light!).

11013

Are we "doing it" this week? ;)

[Paazuzu]

Looks the goods! Super keen to do mine asap now.
How hard was it?

Pretty straightforward - make you have a dremel for all the cutting that's required!

[Paazuzu]

Are we "doing it" this week? ;)

What are you suggesting Gav? :P Haha.

I'll be organising a time with you very soon - hopefully in the next couple of weeks!! Stage 2 here we come!

Just need to get the friggin' spoiler back on today.

[noone]

then some decent tyres and suspension so you can get some of that torque down...

[Paazuzu]

Car is all back together but I appear to have developed a leak somewhere in the intercooler piping. I get a loud whistle on boost. Damnit.

I didn't put sealant on the sensor so wondering if that's it. It's on very tight though so I'm guessing its one of the other joins.

Going to have to leave it to later in the week to solve due to work.

[Paazuzu]

then some decent tyres and suspension so you can get some of that torque down...

That will be the next step...once I've gathered the dosh.

[seangti]

That will be the next step...once I've gathered the dosh.

You're welcome to check/try out my cars for suspension alternatives. Very happy with both, silver one is lower, red one handles better. Ride wise both are really good, red one perhaps marginally better ride but have really only driven highway and racetrack, yet to try back roads.

[Paazuzu]

You're welcome to check/try out my cars for suspension alternatives. Very happy with both, silver one is lower, red one handles better. Ride wise both are really good, red one perhaps marginally better ride but have really only driven highway and racetrack, yet to try back roads.

Thanks Sean - I will definitely take you up that offer! Not sure what I want yet so great to try a couple of options.

[Barnz]

nice 1 man!

[Paazuzu]

Air leak is now sorted. Tightened up all the clamps and did a test run. No more whistling and all the pipes/joins seem to be holding well.

Tightened them up again before putting the spoiler back on! At least I'm getting quick with taking the spoiler off lol

Car feels crisp and pulls a bit harder so very happy with the install. Cheers to Gav and Sean for the advice :)

[rollehgoo]

seeing as though yours went great i cant wait to get mine underway!