R56 Intercooler solutions
Intercooler solutions
So while fishing around for custom intercooler setups i was searching many euro cars that have the same supplier of parts.
Fishing around i found this from a c70 turbo... look familiar (1)?

I am trying to see if i can find a cheaper solution before dishing out the dollars for an alta kit. As long as the dimensions and flow rate are close to the competitors there shouldn't be a problem.
From putting together my S2k's intercooler kit i went back to the source at
http://www.siliconeintakes.com/
They have inexpensive(not cheap) cores but none with the tube back configuration.
I was also putting together a piece from
http://www.bellintercoolers.com/pages/AAAssm.html
This topic has come up before but all i read was rants about why
.
Any one on this forum had any success with a custom setup. all searches came up dry.
Fishing around i found this from a c70 turbo... look familiar (1)?

I am trying to see if i can find a cheaper solution before dishing out the dollars for an alta kit. As long as the dimensions and flow rate are close to the competitors there shouldn't be a problem.
From putting together my S2k's intercooler kit i went back to the source at
http://www.siliconeintakes.com/
They have inexpensive(not cheap) cores but none with the tube back configuration.
I was also putting together a piece from
http://www.bellintercoolers.com/pages/AAAssm.html
This topic has come up before but all i read was rants about why
.Any one on this forum had any success with a custom setup. all searches came up dry.
I bought the Alta. It just wasn't worth my time to find a core, fabricate endtanks with the correct orientation of the outlets, then weld it it up. (yes I have an AC/DC square wave tig welder, doesn't everyone?...lol)
I have the Helix FMIC and quality and fit is flawless. BTW I had mine coated with a heat dispersant black coating and I don't really know how much the coating adds to the cooling capacity but it looks good installed.
I have Alta on mine and I would not recommend it. It just did not fit right. The back end is basically flat unlike what's pictured above on the Helix. In my opinion the Alta design did not utilize the space inside the bumper well. Also the hose outlet did not line up with the stock hose. I had to put in a lot of effort to get the hose line up to get it clamped on. I'm concerned with the tension between my stock hose to the FMIC. Most likely I will have to upgrade my FMIC hoses to minimize the bad Alta FMIC design.
If I can do it again I would pick Forge or Helix. My first choice is Forge because it had bolt on mounting points. In contrast my Alta relied on the hose to secure it on, and the bumper to basically sandwich the FMIC. I have to admit my Alta is still hanging on and have not fallen off or rattled, but never the less the egneering design effort on the Alta does not match Forge's or Helix.
I recommend you do your own research on your options and compare the FMIC very closely. In fact there are many topics discussed in NAM regarding this. I have Alta and I do not recommend it.
I also have Alta's Turbo back and dont recommend it. The exhoust note has too much load annoying drone noise. I would pick JCW or AC Schnitzer exhoust kit instead. Sorry for going off topic.
If I can do it again I would pick Forge or Helix. My first choice is Forge because it had bolt on mounting points. In contrast my Alta relied on the hose to secure it on, and the bumper to basically sandwich the FMIC. I have to admit my Alta is still hanging on and have not fallen off or rattled, but never the less the egneering design effort on the Alta does not match Forge's or Helix.
I recommend you do your own research on your options and compare the FMIC very closely. In fact there are many topics discussed in NAM regarding this. I have Alta and I do not recommend it.
I also have Alta's Turbo back and dont recommend it. The exhoust note has too much load annoying drone noise. I would pick JCW or AC Schnitzer exhoust kit instead. Sorry for going off topic.
Agree with everyone here...
Just get the Helix. It's cheaper than Alta's too (especially if you can get it on a group buy...not sure if they still are doing them)
It's not worth the headache and money of trying to custom fab an intercooler when someones already done all the design, fabbing, work and testing for you...especially when they've done it well. If you can come up with some revolutionary design then by all means, go for it! I don't think anyone has done anything to different than any of the i/c's out there already. Cept maybe czar....who removed the intercooler entirely and put a piece of titanium piping in its place
Just get the Helix. It's cheaper than Alta's too (especially if you can get it on a group buy...not sure if they still are doing them)
It's not worth the headache and money of trying to custom fab an intercooler when someones already done all the design, fabbing, work and testing for you...especially when they've done it well. If you can come up with some revolutionary design then by all means, go for it! I don't think anyone has done anything to different than any of the i/c's out there already. Cept maybe czar....who removed the intercooler entirely and put a piece of titanium piping in its place
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I will most likely be buying one, but im used to having custom setups, just the end tank orientation is the part that has hung me up.
I was leaning towards the alta... taller, and the part that is exposed to exterior flow is thicker and taller. I understand the step core design, but the stepped core part is covered 50% by the lower bumper no?
They are both effective... just wonder which one is that much more.
The helix is 1" up top and the alta 2"... the Helix has the stepped core design the alta does not. making it fit right doesnt phase me because i have always "made" things fit.
What are your opinions?
Not a battle to start but a real look at both.
Has anyone had one and switched to the other with noticable changes
doubtful but i would like to hear some educated opinions other than the rants in previous posts.
I was leaning towards the alta... taller, and the part that is exposed to exterior flow is thicker and taller. I understand the step core design, but the stepped core part is covered 50% by the lower bumper no?
They are both effective... just wonder which one is that much more.
The helix is 1" up top and the alta 2"... the Helix has the stepped core design the alta does not. making it fit right doesnt phase me because i have always "made" things fit.
What are your opinions?
Not a battle to start but a real look at both.
Has anyone had one and switched to the other with noticable changes

doubtful but i would like to hear some educated opinions other than the rants in previous posts.
I like the Helix as well. It is not covered by the bumper as you mentioned. There is no need to trim the plastic grates to fit and the ends also fit without any issues. Had it for almost 20 months now, as part of the first group buy early last year and have been real happy with it.
I like the Helix as well. It is not covered by the bumper as you mentioned. There is no need to trim the plastic grates to fit and the ends also fit without any issues. Had it for almost 20 months now, as part of the first group buy early last year and have been real happy with it.
So all of the stepped part of the intercooler is exposed, because i thought the stepped par filled the space of the stock IC which 50% of the stock is covered
All current FMIC have the first 2 lower tubes/fins, shielded by the lower section of the front bumper, this does not have any detrimental effect, on the FMIC cooling ability, regardless to the design being stepped or otherwise.
A further note, unless you introduce a air diverter cowl, to guide the air to pass through the intercooler fins, air will always take the path of least resistance! And in this case around rather than through.
A further note, unless you introduce a air diverter cowl, to guide the air to pass through the intercooler fins, air will always take the path of least resistance! And in this case around rather than through.
Last edited by czar; Oct 20, 2010 at 09:10 AM.
All current FMIC have the first 2 lower tubes/fins, shielded by the lower section of the front bumper, this does not have any detrimental effect, on the FMIC cooling ability, regardless to the design being stepped or otherwise.
A further note, unless you introduce a air diverter cowl, to guide the air to pass through the intercooler fins, air will always take the path of least resistance! And in this case around rather than through.
A further note, unless you introduce a air diverter cowl, to guide the air to pass through the intercooler fins, air will always take the path of least resistance! And in this case around rather than through.
Thats exactly at what im getting at, up top the alta is 2 inches, in the airflow stream. The helix is only 1 inch in the airflow stream so i wonder if the difference is worth the buck which it isnt but i could buy one off of someone off here for about the same as a helix
Any intercooler is only as good as the cores ability, and although not all are equal in height, you have to decided if that extra 1 inch, is worth the extra $$$
Another quick note, what most aftermarket company's rely on , in the case of the intercooler is, they rely on the core volume to help in the cooling, (poor core quality) rather than a good quality core of a smaller size to produce better cooling ability.
Another quick note, what most aftermarket company's rely on , in the case of the intercooler is, they rely on the core volume to help in the cooling, (poor core quality) rather than a good quality core of a smaller size to produce better cooling ability.
Last edited by czar; Oct 20, 2010 at 09:42 AM.
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