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timmus

All-Alloy Intercooler Group Buy (Alu Ladeluftkühler Sammelbestellung)

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timmus   

Hello fellow friends of the Audi A2!

 

First of all, let me apologise for writing in English. I lived in Germany as a young child and so my spoken German is good, but my written German and my German engineering vocabulary is terrible. Please excuse me!


My name is Tom and I have been an active member of a2oc.net for many years under the username Timmus. I do a lot of retrofitting for UK-based A2 owners and have upgraded hundreds of A2s with optional extras like cruise control, Bose, multifunction steering wheel, rear electric windows, etc, etc. Recently, I decided to upgrade the engine of my A2. I call it TDI120. You can read all about it here: http://www.a2oc.net/forum/showthread.php?32986-TDI120-My-New-Engine

 

As part of this project, I developed an all-alloy intercooler to finally solve the reliability problems of the factory intercooler. As many A2 TDI drivers will know, the original intercooler fitted by Audi is poorly made and unreliable. A failed intercooler results in the car entering 'limp home mode'. Replacements won't be available from Audi forever and, even whilst they are, the poor reliability of the original unit remains. So, a replacement that offers both total reliability and increased effectiveness is needed.
The problems of the original Audi intercooler and current third-party replacements are documented here: http://www.a2oc.net/forum/showthread...492#post281492

 

With this post, I hope to open a group order for the all-alloy intercooler, as used in my TDI120. The all-alloy intercooler solves all reliability issues, offers increased cooling capability and fits the car as standard. In order to fit this intercooler, there is no need to modify any components of the car in any way. A full description of all the benefits of this intercooler, and how these benefits are achieved, can be read here: http://www.a2oc.net/forum/showthread...493#post281493

 

5968f0d442e87_6.1-TimmusIntercooler.thumb.jpg.89b10919304f88387fcffc04fc87efd2.jpg

 

For comparison, here is the original intercooler fitted from factory:

5968f0ce83f37_6.2-AudiIntercooler.thumb.jpg.965e87f8447a96157a5c14021e081d6b.jpg

 

The all-alloy intercooler is manufactured by Pro Alloy Motorsport, a UK-based, FIA-approved automotive manufacturer who specialise in race-standard heat exchangers. They have manufactured intercoolers, coolant radiators and fuel systems for Ferrari, Lotus, Noble, Aston Martin, Cosworth, various performance Audis, countless classic cars and many others. Their expertise with alloy manufacturing means they've also been heavily involved in the restoration of Bluebird K7. Pro Alloy Motorsport's website can be seen here: http://www.proalloy.co.uk/
Note that this intercooler for the A2 TDI is not available directly from the manufacturer.

The intercooler that Pro Alloy Motorsport produce for the A2 uses the later 12mm MAP sensor. If your A2 currently uses the older 18mm sensor, a new 12mm sensor will be needed. If your A2 does not have a MAP sensor fitted in the intercooler (such as the TDI90), then a blanking plate for the sensor hole will be provided. All intercooler kits are supplied with bolts suitable for mounting the MAP sensor or the blanking plate.

 

I think I am correct in saying that this intercooler is also suitable for the 1.2 TDI. If somebody could please confirm that the 1.2 TDI uses the same size intercooler as the 1.4 TDI, I would be very grateful.

The total cost of the intercooler is £495, though this may reduce slightly if a particularly large number of orders is received.
Postage costs are not included. This will vary depending on your location, but I guess it will be about £25 for most of Germany.

The intercooler comes with a 12-month warranty against manufacturing defects, but, if installed properly, it should last as long as the A2 itself. The company who manufacture the unit have tested it to 100psi, so the A2 turbo will never break it! The manufacturer describe themselves as "world champions in customer goodwill", so if you have any problems outside of the standard warranty, they will be happy to help.

Should you wish to purchase an all-alloy intercooler, please post in this thread and send me a private message containing the following information:
- First name and surname
- Full address (including street name, house name/number, town, postcode)
- Email address
- The number of intercoolers you wish to order
- Your model of TDI (75PS, 90PS, 1.2 TDI)
Once I have received this information, I will send you a private message and/or email with my payment details.

I hope to leave this order phase open until 31st Aug 2017. Manufacturing will then begin and hopefully everybody will receive their intercooler by the end of September.

Depending on demand, there may be further order phases in the future, but this cannot currently be guaranteed. As such, if you want one now or don't want to risk your current intercooler dying after manufacturing, get your name on the list! Whilst the all-alloy intercooler can be considered a performance product, it is also a product designed for reliability. Therefore, no matter what the nature of your relationship with your A2, this upgrade makes sense for all.

 

Although I have been offering A2 services in the UK for many years and have many happy customers, this is the first time I have organised a group buy. So, if anyone here has any advice to offer, I'm very happy to listen.


Mit freundlichen Grüßen,

 

Tom

 

Total orders received so far: 10

 

Moderators: If I have broken forum rules with this post, please let me know and advise me on how I can make this opportunity available for the members of this club. Thank you!

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bret   

Hi,

 

I'm reasonably sure you're not breaking any rules and I'd like to say hello and Welcome to the dark side :)

 

A question that will be raised shortly will involve TÜV and their approvals, if such a modification requires one (which it probably does). Any thoughts on how we could get at least one car through that process with minimal (financial) pain and a reasonable timescale? That would probably mean a sample being made available relatively soon and at a reasonable price so someone can do battle with the paperwork, from which everyone else can profit... or do ProAlloy have experience of certifying with TÜV for an ABE?

 

This is going to be interesting @Sven94 @Nuerne89 @HellSoldier

 

 - Bret

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timmus   
vor 2 Stunden schrieb bret:

Hi,

 

I'm reasonably sure you're not breaking any rules and I'd like to say hello and Welcome to the dark side :)

 

A question that will be raised shortly will involve TÜV and their approvals, if such a modification requires one (which it probably does). Any thoughts on how we could get at least one car through that process with minimal (financial) pain and a reasonable timescale? That would probably mean a sample being made available relatively soon and at a reasonable price so someone can do battle with the paperwork, from which everyone else can profit... or do ProAlloy have experience of certifying with TÜV for an ABE?

 

This is going to be interesting @Sven94 @Nuerne89 @HellSoldier

 

 - Bret

 

Thanks Bret. I have for a long time used A2-freun.de as a resource, but have never posted. I can read German perfectly well as long as it doesn't include a huge number of abbreviations and slang terms for components, etc. I have met a few members from this club though, so I know it's not really the dark side. :-)

The TÜV is something I had considered but thought I'd post anyway and hope that someone would provide further advise.

ProAlloy sell from their website to Germany on a weekly basis. All the intercoolers that you see here are available to German customers and they sell regularly: http://www.proalloy.co.uk/cgi-bin/sitewise.pl?act=sect&s=1609&pt=52_1608&id=proalloy

I spoke with ProAlloy earlier today about the TÜV issue and was advised that it wasn't a problem. The only times they have had to get involved in TÜV testing is for fuel tanks.

Cheers,

 

Tom

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vor 9 Minuten schrieb timmus:

Weiß jemand, warum ich meine Beiträge nicht mehr bearbeiten kann?

Das ist eine generelle Regel hier: Beiträge können nur eine bestimmte Zeit nach dem Absenden bearbeitet werden.

 

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timmus   
vor 36 Minuten schrieb Phoenix A2:

Das ist eine generelle Regel hier: Beiträge können nur eine bestimmte Zeit nach dem Absenden bearbeitet werden.

 

 

Ah, ok. Es war nur für Rechtschreibfehler.

 

Hallo, Andre. :)

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bret   
10 hours ago, timmus said:

Weiß jemand, warum ich meine Beiträge nicht mehr bearbeiten kann?

 

We've had problems in the past (<5 years ago) with large quantities of posts being edited by unhappy users so we've made it rather harder for it to happen again. 

 

 - Bret

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A2Hesse   

Its almost 600 Euro...  for me way too expensive, sorry... if it was cheaper (minimum half price) i would be very interested, but not at this cost.

 

Anyway a great project. Thanks for that!

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A new "cheap" Intercooler costs about £60 (~65€) in germany...

 

You could Buy 10 Intercoolers and change it every 6 years for the Price of one full alloy one...

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cmpbtb   

Additionally, you can get a way bigger, plug&play and robust intercooler from A2 Cars for roughly the same price...

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timmus   
Am 17/07/2017 um 20:56 schrieb frosch 999:

At a lower price
interest

 

Am 18/07/2017 um 12:43 schrieb A2Hesse:

Its almost 600 Euro...  for me way too expensive, sorry... if it was cheaper (minimum half price) i would be very interested, but not at this cost.

Anyway a great project. Thanks for that!

 

Am 18/07/2017 um 12:47 schrieb HellSoldier:

A new "cheap" Intercooler costs about £60 (~65€) in germany...

You could Buy 10 Intercoolers and change it every 6 years for the Price of one full alloy one...

 

Hi guys,

 

You are absolutely right; unfortunately, it is quite expensive. This is because the manufacturing is expensive and because the numbers are always going to be quite small. Unfortunately, it simply isn't possible to make this product any cheaper. Also, it is a comparable price to comparable products. If you look at the intercoolers that are made by ProAlloy (here: http://www.proalloy.co.uk/cgi-bin/sitewise.pl?act=sect&s=1609&pt=52_1608&id=proalloy), you will see that they all cost approximately this much. Be aware that there is no value-added tax (Mehrwertsteuer) on the prices you see on the ProAlloy website, but the price listed in this thread is inclusive of tax. I wish these could be made available for £250, but that's impossible.

You can, of course, buy many cheap intercoolers for this amount of money. However, you then need to change it regularly and that can get boring! Most people would probably prefer to fit one reliable unit and then forget about it.

 

Regards,

 

Tom

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timmus   
Am 18/07/2017 um 12:51 schrieb cmpbtb:

Additionally, you can get a way bigger, plug&play and robust intercooler from A2 Cars for roughly the same price...

 

This is very true. However, bigger is not always better. You can read about the history of the Forge intercooler and the problems that arise from its size here: http://www.a2oc.net/forum/showthread.php?32986-TDI120-My-New-Engine&p=281492#post281492

Read Section 5 "Compromises in Existing Choices" and Section 6 "A No-Compromise Solution".

 

Also, for UK customers at least, the Forge intercooler is not available by postal order: it has to be purchased and fitted at the same time. We in the UK cannot just buy the intercooler alone.

 

The ProAlloy intercooler is available by post, meaning you are free to fit it yourself or have it fitted by a garage of your choice. Also, unlike when fitting the Forge intercooler, you can keep the air scoop and no parts of the car need to be cut or modified in any way.

 

Grüße,

 

Tom

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timmus   

5 weeks to go in which to order an intercooler.
This could be a once-only opportunity. There's no guarantee that there'll be another production run after this one.

Cheers,

Tom
 

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