This is my version of the Welly cooler, for the A3. This arrangement is for a ko3 framed turbo, and should work with minimal/zero trimming of the pipes/silicon. Ko4 fitment is slightly different, replacing the turbo outlet pipe with a 54-63mm silicon reducer.
This is the core, as owned by many on here already:
eBay - The UK's Online Marketplace
it’s a beast, and it’s SUCH good value it’s unreal.
To fit that, you’ll need to cut the back of the crash bar out, but that’s dead easy and takes 5 minutes with a grinder.
As for mounting height, I opted to hang mine with around 6’’ of the core hanging below the crash bar, and this seemed to work well with the A3 bumper. You can bring it up a BIT more, but any higher and it fouls the top of the bumper and back of the grille, any lower and it’ll hang out the bottom!
To mount that I used a length of 30mm Angle section alloy bought from B&Q for about £7. that’s just secured on little bits of box section either side of the rad. All very simple stuff, you can see pics on page 26/27 of my build thread.
As for pipes, the cold side is VERY easy.
You will need:
1x 76-63mm 90 degree reducer in silicon
1x 63mm 90 degree silicon bends
1x 63mm 90 degree alloy bend
1x 63mm straight 100mm alloy coupler.
It’ll look like this:
Reducer off the core > coupler to join up the next silicon bend, > then the alloy 90 takes you into the standard throttle body pipe. Simples.
As for the hot side, it’s a BIT more tricky.
You will need:
1x 76-63mm 90 degree reducer in silicon
1x 63mm 90 degree silicon bends
2x 63mm 90 degree alloy bend
1x 63mm x 300mm straight alloy pipe
1x 63mm 45 degree alloy bend
1x 63mm 45 degree silicon bend
1x 51-63mm straight silicon reducer to go onto the turbo outlet.
1x 63mm straight silicon coupler.
The layout:
51-63 reducer straight onto the turbo, pointing upwards.
> alloy 90 degree bend into that, pointing forwards towards the pax side headlight. Coupler on the end of that into:
>45 degree alloy bend into that, coming over the rocker cover
>45 degree silicon bend to take the route downwards part the starter motor
> 90 degree silicon bend on the bottom, pointing outwards towards the pax wheel.
> 90 degree alloy bend, takes you out through the side of the undertray side panel, and ends up pointing forwards below the headlight
> into the 76-63 90 degree reducer pointing back towards the centre of the car, and connected onto the core
Top side setup will be very similar to this: (this is my ko4 layout)
Although the connection onto the turbo is slightly different, because your turbo’s sit a lot lower than my ko4 frame.
All the silicon bits and alloy bends came from Mr. Silicon on ebay:
eBay My World - mrsilicone
As for the clamps, I used JCS Hi-Grip stainless steel clamps, you need the 60-80 clips for all the 63mm pipework, 2x 70-90 clips for the core connections, and then a 50-70 for the turbo connection. Count the number of joints in the system to work out how many 60-80’s you’ll need, it’s about 12 I think.
The core was £80, my pipes from Mr silicone came to £140, and I spent about £30 on hose clips.
