Hi David,

Your hi powered TDI observations are quite interesting. Especially
that you can keep it cool enough despite the increased power.

FYI: My 1.9TD has nearly the same EGT readings: around 400C
at 100-110 km/h highway and up to 800C in long hard climbs.

Jake Russell who was active on the Diesel list several years
ago found that there was a direct coupling between EGT change
and intercooler efficiency. Ie at 15psi boost the post turbo
temp is often in the 100C range. Using an oversized intercooler
(Jake found that the Audio 5000 one worked quite well, but it's
a lot bigger than the TDI one), the post IC temp can be brought
to almost ambient (e.g. 20C). Then measuting EGT with and without
intercooler the EGT dropped nearly the same amount as the intake temp.

I tried to put the big Audi 500 IC in my Vanagon setup, but it
is a tight squeeze, and I never found a good reliable solution.
(Same setup as yours with IC behind drivers side tail light).

I was curious if you have before and after IC temps for different
boost pressures and airflows through the IC?

How do you wire your IC fan? Always on? Or temp controlled?
At highway speeds does it need to be on? (I'm thinking there might
be a pretty good airflow through the air channel anyway)

Cheers,
Martin