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Audi B5 RS4 | Custom Sidemount Intercoolers | 20/07/11

One of the main modifications people make to the Audi B5 RS4 is to update the intercoolers which is generally either uprated Sidemount Intercoolers (e.g. Wagner) or a custom Frontmount Intercooler. The former is a well tried and tested kit which gives great results, but is over £1500. The later is a cheap option on the surface (around £800 for an "off the shelf" kit) but on the RS4 you will need a new oil cooler and related pipework along with a PAS cooler of some sort. You also loose the electric radiator fan though some ditch it all together whilst others fit a pair of smaller fans.

Either way, it's an expensive (but worthwhile) modification. Therefore I have decided to make my own Sidemount Intercoolers with the assistance of some good friends. The starting point of this is with the cores, as pictured below. I researched the current "Uprated" Sidemount Intercoolers in the marketplace and their respective size of core, settling to go with the same size core as the Wagner Intercoolers - well if it works for them why chance it!

Next step is to work out how the endplates need to be fabricated along with the mounting points and we're in business.