Now that it is all set and done:
- I went with an ebay kit for $300.
- material quality good, T-bolts, silicone; rounded 'things' at the ends of the tubes
- intercooler material good (mounting brackets top and bottom)

Fit: ok, very tight (not the 'stick together and it falls into place' type)
Had to give up one of the 2 horns. Connection/routing of the (is it the N71?) line was impossible (needed to make a 180 turn in tight space; tubes collaps. Ended up using 2 threaded 90 elbows (I think 3/4 or 1 inch) used for sprinkler systems: works great.

Advice: My 20x6x2.75 thick IC was not a good fit. If I had to do it again, I would go the same route, but choose a 2.5 thick, which makes life easier (maybe even with the over fit of the pipes).

Conclusion: some elbow grease, some head scratching. But can't beat $300.

Note: with no changes (same TAP chipped ECU, etc) max boost on gauge went from a max of 17 psi (majority 15-16 psi) in 40 degree to consistently 18.5 in 80 degree (not sure if this can be assigned to the intercooler; I do not have before/after logs of the intake air temp with VAGcom).

 

Your boost was higher because it was 80 degs outside vs the 40 degs when it was 17psi.

 

someone needs to definately step up and make a cheaper intercooler i want to get one but i cant justify shelling out 900 for a racetec i know it can be done for cheaper off ebay but i don't have the parts to make it work when something doesnt fit right. ps. mike2ptzero where did you get your hood?

 

Audacity: install the FMIC is quite some work, even the 'perfect' fit $900 kits will require hours of work (the front of the car has to come off, factory plumbing removed, etc.).

Adding an hour or 2 of knuckle grease to get a $300 kit like mine to fit well nets $300 per hour (never been paid that much for my knuckle grease).

Only "I like to have it and will throw money at it" need to apply for $900 kit.

 

vtraudt. do you have any pictures of what you did? your tale of threaded elbows and sprinkler systems has me confused.

 

Audacity, I will put up what I have (won't hurt). But the part with sprinkler system may only be applicable to my setup (and I don't have a photo).
Below are some pics. The problem was that the rubber piece has the hose molded on (no connector) and the alu piece has the (male) stub. And in my case (not sure if it is the best way) the male stub was 180 degree rotated to where the hose is. Making a 180 degree loop with a rubber hose will pinch it given the available space (and run routing in half around the world).




Above: rubber piece with molded on hose

Above: male alu to connect to male factory; 180 dgree

So I made a 180 by using 2x 90 degree plastic elbows (threaded male/female on one side, barbed on the other; ID to fit the hose, I think 3/4 inch), and 4 hose clamps.

Here are a bunch of pics.

http://s853.photobucket.com/albums/a...20Intercooler/

 

A racetec FMIC should only take 1 hr to install if the person has installed a FMIC before. Just have to line up the pipes correctly, put the bumper back on and its done.


Took me and a friend about 45-60 minutes to install a ER Comp on his B6. Did it right before taking the car to the track.

 

If you look you might be able to find someone selling a Racetec for much less. I just saw someone on VOrtex selling a brand new one but it is for a B6 A4.


My hood is a custom Fiber Images vented B5 hood. But they dont offer the vented hood anymore, just the non vented.

 

do they still offer them with the twin turbo inlets? ive seen them with them but they have other lines in them which yours doesnt. and vtraudt you used the godspeed kit, looks like it should work if i go this route ill probably get it in 2.5 inch im not looking for any big turbo power, i just want to run the pc-16 program. thanks this has been real helpful.

 

The 2.5 inch is the better choice. I chose the 2.75 because I was under the impression that I have tons of depth to play with under the bumper reinforcement (not true). Ditto height and width: 20x6x2.5 is all that can be hidden under the B5 bumper without major grinding (I had a grind quite a bit of plastic from the inside of the bumper).