**TT-RS**Project 750hp
#79
02-27-2013, 01:12 PM
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Join Date: Jan 2011
Location: (in my garage welding something vicious)
Posts: 1,505
Rep Power: 103 
#86
08-03-2013, 07:37 AM
Join Date: Jun 2011
Location: London
Posts: 89
Rep Power: 17
UPDATE:
Since last posting ive bought a bigger intercooler. This is the forge race version, so bigger than their sport, and this time in black to go with the stealth look. Forge say they gained 50hp from these new intercooler over their sport version on the TTShops hybrid ttrs.
A friend of mine also on a hybrid turbo tuned by gained 40hp from fitting this intercooler and new mapping, so it only made sense for me to upgrade, and possibly I wont need to run WMI now
Heres the findings of my mate Alex on his car.
Results in from new Forge race intercooler on my TTRS
Got back yesterday after a long day at MRC, as some of you know I was having trouble with intake temps.
Starting both runs with a soild intake temp of 10C we saw that the stock cooler was going +65c so upto max 75c. With the forge race we were seeing the intake rise + 10c to + 15c so max 30c.
Very happy with it, nice piece of kit, well made.
Blue = stock cooler
Black = Forge race
Since last posting ive bought a bigger intercooler. This is the forge race version, so bigger than their sport, and this time in black to go with the stealth look. Forge say they gained 50hp from these new intercooler over their sport version on the TTShops hybrid ttrs.
A friend of mine also on a hybrid turbo tuned by gained 40hp from fitting this intercooler and new mapping, so it only made sense for me to upgrade, and possibly I wont need to run WMI now
Heres the findings of my mate Alex on his car.
Results in from new Forge race intercooler on my TTRS
Got back yesterday after a long day at MRC, as some of you know I was having trouble with intake temps.
Starting both runs with a soild intake temp of 10C we saw that the stock cooler was going +65c so upto max 75c. With the forge race we were seeing the intake rise + 10c to + 15c so max 30c.
Very happy with it, nice piece of kit, well made.
Blue = stock cooler
Black = Forge race
#87
08-03-2013, 07:40 AM
Join Date: Jun 2011
Location: London
Posts: 89
Rep Power: 17
Then the turbo kit mounted on the motor. APR then decided to remove the kit and send it off for a special coating, so off it came and shipped back to the states.
My helix twin plate clutch with lightweight SMF then finally arrived like 9 months after commisioning helix to develop one...
My helix twin plate clutch with lightweight SMF then finally arrived like 9 months after commisioning helix to develop one...
#88
08-03-2013, 07:44 AM
Join Date: Jun 2011
Location: London
Posts: 89
Rep Power: 17
And as of progress up to today:
APR motorsport released their own intercooler, its the biggest on the market with the most frontal area so Ive ordered one of those aswell. I'll just sell the two forge ones on.
Also a carbon carbon clutch kit is being developed, so I will upgrade to that aswell.
Specs of the APR intercooler:
Product Page
The APR Intercooler System dramatically lowers charge air temperature and resists heat soak far better the TT RS’s factory intercooler system. Through a massively increased frontal surface area, superior intercooler core design and smooth, cast end tanks, APR’s engineers were able to create an intercooler capable of supporting power levels well beyond that of the factory unit. Expect increased horsepower and torque and dramatically prolonged performance.
Intercooler Ambient Air Fins
Each unit uses a high quality, bar and plate core with staggered and louvered fins. The Intercooler’s exceptionally tall design and fin structure exposes the core to a greater volume of airflow than possible with the factory or similar aftermarket short and thick core designs. With more of the intercooler directly exposed to the elements, cooling effectiveness dramatically increases.
Intercooler Charge Air Fins
Internally, the APR Intercooler System features a staggered and louvered fin design with a core density chosen as a balance between cooling effectiveness and pressure drop. Due to the core’s massive volume, the balance was easily adjusted to favor minimal pressure drop while still providing superior effectiveness compared stock and similar to stock designs.
Intercooler Rear with Support Brace installed
The intercooler’s maximum size and frontal area is directly related to packaging constraints found at the front end of the vehicle. Intercooler units located in the factory location are design limited resulting in increased volume primarily through expanding the depth of the system. Unfortunately increasing depth only slightly increases the intercoolers effectiveness compared to increased frontal surface area. APR’s Intercooler System includes a reengineered front-end support brace constructed from billet aluminum to maximize packaging constraints. The low profile support brace resides near the factory location and no longer blocks the intercooler from front-end airflow. The bar’s inner design features a weight saving grid, which also aids in airflow through the core.
The intercooler core and brace are both black to remain stealthy behind the TT RS’s massive grille. The black chip and corrosion resistant coating does not alter the thermal effectiveness of the intercooler core. During testing APR’s Engineers were unable to measure a difference in temperature between the coated and non-coated system during both dyno and road tests. This was further backed up with matching dyno performance between coated and uncoated systems equaling each other.
More Photos : Click to Enlarge
Testing Data - Dyno
The Test below demonstrates the intercoolers ability to cool intake air temperature even under brutal conditions. Six back-to-back pulls were preformed with absolutely no cool down between runs. The APR Intercooler’s first run was conducted in slightly worse conditions than the stock intercooler, but it was able to keep the intake air temperature at redline lower than stock even after the sixth back to back pull! The dramatic rise in temperature from the stock intercooler cost the TT RS valuable horsepower on the dyno and averaged over 25 HP less than the APR unit across the six runs.
Testing Data - Street
APR’s Engineers set out to further prove each Intercooler’s effectiveness by testing in real world conditions on the street. Four back-to-back 20-130 mph pulls were conducted with both the factory and APR intercooler unit while various data points were collected with APR’s ECU Explorer data logging suite. While APR’s Engineers made every effort to keep starting temps identical between the two intercoolers, unfortunately conditions worsened while testing the APR unit as ambient temperature increased.
The rise in temperature was still no match for the APR intercooler unit. Pull after pull, the intercooler was able to cool charge air temperature below the actual starting temperature! The stock intercooler unfortunately experienced a rapid temperature increase and on average ran 14C higher than the starting temperature. The intake air temperature results collected on the street mimicked that of the data collected on the dyno further backing the power associated with each unit.
APR motorsport released their own intercooler, its the biggest on the market with the most frontal area so Ive ordered one of those aswell. I'll just sell the two forge ones on.
Also a carbon carbon clutch kit is being developed, so I will upgrade to that aswell.
Specs of the APR intercooler:
Product Page
The APR Intercooler System dramatically lowers charge air temperature and resists heat soak far better the TT RS’s factory intercooler system. Through a massively increased frontal surface area, superior intercooler core design and smooth, cast end tanks, APR’s engineers were able to create an intercooler capable of supporting power levels well beyond that of the factory unit. Expect increased horsepower and torque and dramatically prolonged performance.
- Dramatically lowers intake air temperature
- Increases horesepower and torque while prolonging performance
- APR intercooler core dimensions: 3.00" x 12.70" x 22.25"
- OEM intercooler core dimensions 3.19" x 6.38x" x 21.75"
- 104% more frontal area and 92% larger core compared to stock
- Pressure tested for leak proof operation
- Smooth cast alumnium end tanks
- CNC machined hose connection points
- Integrated light weight support brace, horn and sensor brackets
- Stealthy black coating does not alter thermal effectiveness
- Full install directions and APR's world-renowned customer support
- Lifetime warranty
Intercooler Ambient Air Fins
Each unit uses a high quality, bar and plate core with staggered and louvered fins. The Intercooler’s exceptionally tall design and fin structure exposes the core to a greater volume of airflow than possible with the factory or similar aftermarket short and thick core designs. With more of the intercooler directly exposed to the elements, cooling effectiveness dramatically increases.
Intercooler Charge Air Fins
Internally, the APR Intercooler System features a staggered and louvered fin design with a core density chosen as a balance between cooling effectiveness and pressure drop. Due to the core’s massive volume, the balance was easily adjusted to favor minimal pressure drop while still providing superior effectiveness compared stock and similar to stock designs.
Intercooler Rear with Support Brace installed
The intercooler’s maximum size and frontal area is directly related to packaging constraints found at the front end of the vehicle. Intercooler units located in the factory location are design limited resulting in increased volume primarily through expanding the depth of the system. Unfortunately increasing depth only slightly increases the intercoolers effectiveness compared to increased frontal surface area. APR’s Intercooler System includes a reengineered front-end support brace constructed from billet aluminum to maximize packaging constraints. The low profile support brace resides near the factory location and no longer blocks the intercooler from front-end airflow. The bar’s inner design features a weight saving grid, which also aids in airflow through the core.
The intercooler core and brace are both black to remain stealthy behind the TT RS’s massive grille. The black chip and corrosion resistant coating does not alter the thermal effectiveness of the intercooler core. During testing APR’s Engineers were unable to measure a difference in temperature between the coated and non-coated system during both dyno and road tests. This was further backed up with matching dyno performance between coated and uncoated systems equaling each other.
More Photos : Click to Enlarge
Testing Data - Dyno
The Test below demonstrates the intercoolers ability to cool intake air temperature even under brutal conditions. Six back-to-back pulls were preformed with absolutely no cool down between runs. The APR Intercooler’s first run was conducted in slightly worse conditions than the stock intercooler, but it was able to keep the intake air temperature at redline lower than stock even after the sixth back to back pull! The dramatic rise in temperature from the stock intercooler cost the TT RS valuable horsepower on the dyno and averaged over 25 HP less than the APR unit across the six runs.
Testing Data - Street
APR’s Engineers set out to further prove each Intercooler’s effectiveness by testing in real world conditions on the street. Four back-to-back 20-130 mph pulls were conducted with both the factory and APR intercooler unit while various data points were collected with APR’s ECU Explorer data logging suite. While APR’s Engineers made every effort to keep starting temps identical between the two intercoolers, unfortunately conditions worsened while testing the APR unit as ambient temperature increased.
The rise in temperature was still no match for the APR intercooler unit. Pull after pull, the intercooler was able to cool charge air temperature below the actual starting temperature! The stock intercooler unfortunately experienced a rapid temperature increase and on average ran 14C higher than the starting temperature. The intake air temperature results collected on the street mimicked that of the data collected on the dyno further backing the power associated with each unit.
#89
08-17-2013, 07:42 AM
I just registered myself so follow your work mate, itīs going to be a stunner, it is isnīt allready!
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#90
08-24-2013, 08:32 AM
Love the build and have been following along from beginning. Best of luck and keep us updated as always.