I've read a lot of recent postings (archives, we don't need no stinkin' archives) on intercooler mods. I think we need to add the big speculation alert to this issue.<p>I agree with RMZ about the basics. I'll rephrase it: How do you know that you need a intercooler modification?<p>Have you ever taken temperature readings? Where? I would strongly recommend taking a reading at the intake manifold, the intercooler face, and the aircleaner port. It is easy to do with a probe and a peak-hold meter (you can tape it on at each location). PLEASE, don't bother to do this on a parked car, it is awaste of time and highly inaccurate (dyno's, too).<p>The intercooler works on air flowing past it, the faster the air, the lower the temperature and the higher the efficiency. I would not change the air ducting around the stock intercooler without some air flow measurements. My fluid engineering tells me that I can't eyeball the best design. Audi did a very good job on this car, and they maximized air VELOCITY past the intercooler. Narrow passages, not big honking exhaust holes, maximise velocity.<p>If, after careful temperature analysis you think you need a better intercooler: Intercoolers with more surface area, AND efficient design, AND proper plumbing all work together to make an improvement. Get anyone of these wrong and you will not be happy.<p>I can't really see a see a need for a different design for my car until I put a KKK 04 on it. The reason is that I don't want oversized-intercooler bogginess and off-throttle stumble. A larger intercooler holds more air, that air stalls when you get off the throttle. The bypass which solves this in the stock setup is not designed for that much air. When the boost is not up, the air needs to flow through all that extra plumbing at just 1 atm to get to the cylinders.<p>I would recommend watercooling first. Aquamist makes a great system that can really take advantage of our huge windshield washer tank. You can use a alcohol/water mix spray it into the intake manifold and spray it on the intercooler at the same time. Can you say: maximum intercooler effectiveness and knock elimination!<p>BTW does anyone actually have a picture of Cathleen?<p>

<br> . . .you could use a bigger intercooler. I believe in pressure first, then temperature. An intercooler that is great with stock boost may have too high a pressure loss at higher boost. If you can limit the pressure drop AND get a good temp drop you've found IC nirvana.<p>Todd W

........jus tell 'em you already have a boyfriend (you can e-mail the guys you're interested in later if you so desire) .......BTW, I've left my e-mail address........just in case........ :-)<p>Rick<br>

just kidding..no offense to you Cathleen...I'm just still jealous of your car =)<p>

It's all in the details. I am a firm adherent to pressure first, then temp. There are some nice spec. tables for intercooler sizing, and you can see that there is a lot of latitude. The stock intercooler fits the specs even over 1 bar, but it's just not super-efficient. Spearco sells some nice, inexpensive units.

Better to be heard/read and not seen??? <p>

Psych! ;-)<p>Don't get excited guys, I think this is the only picture of a woman named Cathleen that you're going to get!<br>

Isn't this "Kathleen"?

<br>To be seen but not heard

C'mon Cathleen, be a player....... :-)<p>Rick<br>

I just posted your name in the title above to get more readership of my stupid note. You've attracted quite a following.

Hey, I'm in the middle of unpacking boxes from moving. I'm not even sure where anything is.<br>Look, I'll post something so you can all just stop badgering me...alright??? ;) <br>

Happy Halloween everyone! This is my "trick". Maybe the real Cathleen will post a "treat" when she gets the chance.<p>Sorry about the forgery Cathleen. It was all in good fun.<br>

2 main factors for intercooler choice will be pressure drop / efficency... For example.. if you install a larger intercooler but it has a large pressure drop you turbo will be forced to work harder to produce the same boost thus costing you an increase in temp next take the cooling efficency of the intercooler into the equations and now you can factor out if you are better than where you started.. thus 2 things to measure.. <p>1) Pressure drop across the intercooler at your max boost. <p>2) Temp drop accross the intercooler at your max boost. <p>From my exp. Spearco has done a good job on all the intercoolers I've purchased from them.. low pressure drop and good efficency.. I've also got a HKS intercooler for a project car I've been working on (84 300ZX turbo).. but have been thinking about using it on my 99 A4.. hmm the A4 is still to new to tweak just yet (only has a 100 miles hehehe) So I may just measure the stocker to death and when I chip the car measure again.. either way getting all the data and doing some analysis is fun anyways.. (and keeps you from wasting money!)