VW T5 Transporter - Making my own CUSTOM Intercooler upgrade

Why just replace parts when you can upgrade or improve at the same time. With my Volkswagen Transporter T5 (pre-facelift) I had intercooler problems, having replaced it once before but now having issues with the factory clips enough was enough! Not having the budget for the forge motorsport intercooler and not liking the way the darkside intercooler mounts, I decided to build my own upgraded fully aluminium intercooler in my home workshop, which flows better air, keeps the temperatures cooler and eliminates the VW clip in pipes!
Watch along and I show you how I tackled this task, including HOW TO remove your front bumper. Its not all glory as with all things so watch to see the ups and downs of this little project.
00:00 Intro
01:23 Measuring for Pipes
04:06 Parts Delivery
04:51 Front Bumper Removal
08:40 Starting to Mock up the new intercooler
11:07 Boost Pipe Modifications
12:45 Making Intercooler inlet and outlet pipes
15:00 Mounting the intercooler
17:25 Old vs New
18:30 Bumper Stud Fix
20:07 Fit up time
24:07 Closer look at it all done
25:38 Outro
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#vw #volkswagen #transporter #t5 #vwt5 #vwtransporter #volkswagentransporter #volkswagent5 #modifiedvans #rjwcustoms #prefacelift #upgrade #howto #intercooler #customintercooler #custom #bespoke #homemade #diy #bumper #frontbumper #fabrication #welding #aluminiumwelding

[@ryanwestwood9254]

Great job 👍

[@RJW_Customs]

Thank you 🙏

[@MrGierosik]

You could have moved it lower once you made the new pipes and fittings. Most of the intercooler is now covered. Additionally, the flow is worse when it is pressed against the bumper.

[@RJW_Customs]

Yes I agree I could have moved it lower down but this was the simplest and cleanest option, yes it's maybe not in the most optimum position but it will still be getting plenty of air flow. Otherwise 90% of cars on the road there radiators would only be working at 50% as they are behind bumpers