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Thread: THS Copy Intercooler review and installation pictorial semi-DIY

  1. #1
    Super Moderator Lucas_R's Avatar
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    THS Copy Intercooler review and installation pictorial semi-DIY

    Myself and Cihan recently purchased a THS copy intercooler from xoxo racing. The same intercooler kit is also available from this seller as well as this seller. I thought i would upload a few pics showing the good quality of this copy as well as some pics of the install.

    The intercooler kit comes with:
    - intercooler (bar and plate construction)
    - 2x silicone pipes
    - 1x aluminium bung adapter
    - 4x T-bolt clamps

    Delivery took approx 2 weeks and the kit arrived well packaged in a big rectangular cardboard box. The intercooler was wrapped in plastic for protection.

    For removal of the bumper bar, you should refer to Marco's DIY here

    And for intercooler installation instructions, refer to the THS instructions here. The THS instructions are for a Mk5, but 90% of it is relevant for the Golf R.

    You will need to purchase approx 14x M6 x 20mm bolts and matching washers. These are used to secure the intercooler to the radiator and also for mounting the a/c condenser.

    Although i wanted to do a comprehensive DIY of the intercooler install, i was working on my own and it was just too hard to lift a 15kg intercooler and take photos at the same time. So unfortunately most of my pics are to show how the intercooler looks and how it fits etc, rather than how to go about installing it.

    The intercooler is a large bar and plate core design and the amount of bars and plates is the same as the real THS. The end tanks are cast aluminium and welded to the core. The cast end tanks have OEM spec moulded mounting points for securing the intercooler to the vehicle.

    Im really happy with how this product turned out as i must admit i was a bit nervous that it might not fit etc. Everything turned out well, the car goes really well now with the revised tune and there are no boost leaks or rattles or squeaks etc.

    Intake temperature differences with this intercooler:

    Initial test - stock intercooler
    Ambient temp: 11c
    Typical temp range during boosted driving: 23-28c
    Average of about 13-15c over ambient temp

    Follow up test - THS copy intercooler
    Ambient temp: 13c
    Typical temp range during boosted driving: 17-23c
    Average of about 6-8c over ambient temp

    Temp readings taken from my P3 guage reading from the OBD port.

    So anyway, here are some pics:

    Old vs New:





    New Intercooler Kit:















    Some pictures from the install – showing the fitment etc:














    Had to modify the aluminium adapter bung slightly to fit. The tabs were a few mm too wide. 5 mins work with a grinder.



    [B]Bung installed:



    Silicone Piping:

    Driver side:



    Passenger Side:

    Last edited by Lucas_R; 09-12-2013 at 03:34 PM.

  2. #2
    Senior Member john2204's Avatar
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    Looks like a interesting replacement that would save you some quid. Logged any temps?
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    Super Moderator Lucas_R's Avatar
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    Quote Originally Posted by john2204 View Post
    Looks like a interesting replacement that would save you some quid. Logged any temps?
    Havent logged intake temps with the new intercooler yet - but i will over the next few days. As a comparison, on an 11 degree evening about a month ago, i did some runs with the stock intercooler and found the intake temps to hover between about 19-28 degrees depening on vehicle speed and rpm.

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    Senior Member tonymy01's Avatar
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    Trying to work out those pics, so it goes in front of the car (and thus radiator), but then the air-cond condensor goes to in front of it? I guess I should have a bit more of a poke around the front of my car to see where the stock intercooler and everything is, with the WRX it was easy ;-).
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    Super Moderator Lucas_R's Avatar
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    ^ yes your right. Radiator is closest to the engine, then intercooler, then a/c condenser at the front closest to the bumper bar.

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    Senior Member xssiiv's Avatar
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    Thanks Lucas

    In case anyone wants an actual install manual I got one with my THS intercooler
    I can scan it in as a pdf and email or PM it to someone so they can host it online

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    Super Moderator Lucas_R's Avatar
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    Quote Originally Posted by xssiiv View Post
    Thanks Lucas

    In case anyone wants an actual install manual I got one with my THS intercooler
    I can scan it in as a pdf and email or PM it to someone so they can host it online
    Thanks Thomas - ive actually got the THS instructions here on my work PC. I'll upload now to a shared drive and put the link in my original post.

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    Senior Member xssiiv's Avatar
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    Awesome!

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    Super Moderator Lucas_R's Avatar
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    Quote Originally Posted by xssiiv View Post
    Awesome!
    Can you try the instructions and make sure they work. They work for me.

  10. #10
    Super Moderator Lucas_R's Avatar
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    For the people who have asked about intake temperature differences with this intercooler, see below some results:

    Initial test - stock intercooler
    Ambient temp: 11c
    Typical temp range during boosted driving: 23-28c
    Average of about 13-15c over ambient temp

    Follow up test - THS copy intercooler
    Ambient temp: 13c
    Typical temp range during boosted driving: 17-23c
    Average of about 6-8c over ambient temp

    Temp readings taken from my P3 guage reading from the OBD port.

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