All-Alloy Intercooler Group Order 2

timmus

A2OC Donor
Hello A2 TDI owners,

4 years ago, the Pro Alloy intercooler was launched for the A2. There are now approximately 30 A2s fitted with this no-compromise component. With this post, I am opening a second group order phase for the all-alloy intercooler, as used in my TDI120: http://www.a2oc.net/forum/showthread.php?32986
Those with the intercooler have reported increased performance and refinement, and reduced fuel consumption and harshness.

This intercooler is suitable for all A2 TDIs, whether they be right-hand-drive, left-hand-drive, 1.4 TDI, 1.2 TDI, etc. If your A2 runs on diesel, this intercooler is for you.

29694

As many A2 TDI drivers will be aware, 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 always be available from Audi and, even whilst they are, the poor reliability of the original unit remains. As such, a replacement that offers both bullet-proof reliability and increased effectiveness is needed.
To read about the shortcomings of the original Audi unit and existing third-party replacements, please click here.

The all-alloy intercooler that is available for purchase here 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.
For a full description of all the benefits of this intercooler, and how these benefits are achieved, please click here.

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. A blanking plate for the sensor hole will be provided for use in A2 TDIs that do not have a MAP sensor fitted in the intercooler (such as the TDI90). All intercooler kits are supplied with bolts suitable for mounting the MAP sensor or the blanking plate.

The total cost of the intercooler is £495.

Postage costs are not included.
For UK orders, there are numerous postage options. It is possible to have the intercooler posted directly to your address for circa £15. Alternatively, they can be posted to a garage of your choice or to WOM Automotive, who are my recommended installer. They can also be posted to me, for delivery at a later date when I'm on a UK-wide A2 tour. If a large number of intercoolers are to be posted directly to me or to WOM Automotive, delivery costs ought to be minimal.
International postage can be arranged. Please let me know your address and I'll supply a quote.

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 (75bhp, 90bhp, 1.2 TDI)
Once I have received this information, I will send you a private message and/or email with my bank account details.

I hope to leave this order phase open for approximately 4 weeks, after which manufacturing will begin. (Provisional order phase end: 29th June, 2020)

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 the manufacturing run, get your name down! 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.

Regards,

Tom
 
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dj_efk

A2OC Donor
@timmus

Have you had any feedback quantifying the gains in efficiency and / or power on an otherwise standard TDI / TDI 90?

It's an interesting product for sure - I just wondered what the real-world evidence of the performance side of its benefits is. The reliability side is of course self-explanatory.
 

mustoes

Member
PM sent. Possible to collect from you in person if I come to have cruise control and upgraded dis installed?
 

timmus

A2OC Donor
@timmus

Have you had any feedback quantifying the gains in efficiency and / or power on an otherwise standard TDI / TDI 90?

It's an interesting product for sure - I just wondered what the real-world evidence of the performance side of its benefits is. The reliability side is of course self-explanatory.
Hi David,

The manufacturer are specialists in the design of heat exchanger systems. Through their own research and development, they've created a variety of different cooler cores for different applications. The ProAlloy intercooler for the A2 is based on their most effective air-to-air heat exchanger core design. This design process was conducted scientifically, taking measurements of flow rates, temperature reduction, air density, etc. This cooler core is then used in the manufacture of all their intercoolers. So, in short, the empirical data exists for the core technology, not for the individual products that are based on that technology.

Of the 30-ish A2s that drive around with a ProAlloy intercooler, many people have reported that their cars are smoother and less agricultural after the installation of the ProAlloy intercooler. People have also said that they're getting fractionally better fuel economy, which would suggest more effective cooling / increased charge air density. Of course, a majority (if not all) of those cars are remapped and have returned encouraging figures. However, as far as I know, nobody with an A2 has done a rolling road test in a scientifically controlled manner to quantify the exact numerical gains that can be attributed specifically to the ProAlloy intercooler. I trust that ProAlloy have got their technology right, though, otherwise they wouldn't be selected as OE manufacturers by performance brands. All the feedback from A2 TDI owners with a ProAlloy intercooler is extremely positive, but I accept that this is anecdotal.

Cheers,

Tom

 

timmus

A2OC Donor
PM sent. Possible to collect from you in person if I come to have cruise control and upgraded dis installed?
Absolutely. Once manufactured, should anybody wish to collect their intercooler from me and have other upgrades installed at the same time, that's ideal.

Cheers,

Tom
 

drewroberts

A2OC Donor
I am one of the lucky ones that has had one of these amazing pieces of engineering fitted to my TDi90. It really does improve lots of very important things reliability, economy, acceleration, progressive and consistent boost pressure and combined with a good remap makes it so that my A2 often keeps up with other faster Audi’s S4’s S3’s and TTS’s etc. If you need one you should invest in one they are unequaled. Perfectly the same dimensions as the original but with better materials and construction it really is a no brainer for any TDi.
 

Attachments

drewroberts

A2OC Donor
I’m pleased you are pleased that I’m pleased. 🙂

This could go on and on.
I’m actually more than pleased I’m ecstatic about the inter cooler. It is quite possibly the best upgrade of all the upgrades I have lavished on Klaudia. Thank you so much for developing it.
 

Edwrai

Member
I’m pleased you are pleased that I’m pleased.

This could go on and on.
I’m actually more than pleased I’m ecstatic about the inter cooler. It is quite possibly the best upgrade of all the upgrades I have lavished on Klaudia. Thank you so much for developing it.
Hi Drew,

How does it improve the car?


Sent from my iPhone using Tapatalk
 

Menno

A2OC Donor
A very nice upgrade. My standard intercooler is installed less then a year ago, so I don't feel the urge to switch now.

In terms of better performance, if it's airtight, it's airtight....... Although it can have a better airflow and bigger cooling surface in comparison with a standard one. So this can give an advantage performance wise.

For sure it's more dependable then the standard intercooler with its crimped on end caps!
 

timmus

A2OC Donor
I hope to leave this order phase open for approximately 4 weeks, after which manufacturing will begin. (Provisional order phase end: 29th June, 2020)
Hi folks,

Having initially stated that this order phase would be open until the end of July, I've brought that date forward to the end of June. The reason for this is that some people need a ProAlloy intercooler rather urgently, and there's no point in needlessly delaying the start of manufacturing by keeping the order open for an additional month. However, if this change of date causes any inconvenience to anyone, the original order phase end date will be reinstated.

Cheers,

Tom
 
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