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TyrolSport Dual UG DSMIC for MK1 Audi TT225
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Although it has been a long-time coming, the wait for a truly effective DSMIC upgrade for the mk1 TT is finally over. TyrolSport has carefully prototyped, constructed, tested, and re-tested many different core sizes and end tank designs on the dyno, on the street, and on the track. After a lengthy R&D process, we finalized a design which performs with incredible efficiency, blows away the stock intercoolers, and fits without a hassle.
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Physical Comparison
Our first goal was to maximize the core volume given the limited space of the TT. We were able to increase core volume by 57.6%. We use only bar and plate intercooler cores, for maximum cooling and efficiency. Pressure drop across the cores utilized is .75psi at 21psi of boost.
- Core dimensions, stock 7” x 3.375” x 7.25” calculated volume: 171.3 in³
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Core dimensions, UGDSMIC 7.5” x 4.5” x 8” calculated volume: 270 in³
The pictures below readily show the difference between the stock TT SMICs, and the upgraded TyrolSport DSMICs. Starting with all-aluminum construction which eliminates any leaks between the core and the plastic endtank on the stock SMIC. Fully TIG welded and built in the USA, using US-sourced aluminum. You will not find any foreign cores, endtanks, or construction when purchasing our products. The size difference in core face and thickness is readily evident.
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We designed the endtanks for flow, and ease of fitment. The intercoolers plug directly into the existing factory piping, and use the factory mounting points, so no additional hardware is necessary.
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Test Vehicle
Our testing was harsh and thorough, as we wanted to make sure that there would be real performance gains even with minimal modifications to your TT.
Our test car was equipped with popular TT modifications:
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For the purpose of the intercooler testing, please remember that the absolute numbers shown on the dyno are not relevant. We are looking for, and examining, the changes in performance that result from improving your existing parts. While your TT may dyno higher or lower than our project car at a different dyno facility, you can expect similar gains when adding our DSMIC kit to your TT225.
At TyrolSport we are firm believers in back-to-back dyno tests, using the same facility on the same day, so that we can eliminate weather and dyno variance. The testing of both the stock and TyrolSport intercoolers was completed in one day, under the following conditions:
- Get car to operating temperature on the dyno, 100C water temp.
- Make 5 dyno pulls on the stock intercoolers, with one minute of cooldown between runs.
- Remove stock intercoolers, and bolt on TyrolSport UG DSMICs, with car still strapped to the dyno
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- Get car to operating temperature on the dyno, 100C water temp.
- Make 5 dyno pulls on the TyrolSport intercoolers, with one minute of cooldown between runs.
- Repeat process again for stock intercoolers to verify initial runs.
- Repeat process again for TyrolSport intercoolers to verify initial runs.
- The bumper cover and headlights were in place for all dyno runs.
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Dyno fans were used on all runs.
We will let the dyno results speak for themselves, as the gains are excellent on the first pull, and truly incredible at the end of the five pulls. Here is a comparison of both horsepower and torque, using only the first pulls from operating temperature. The gains simply by installing the intercoolers are a 10-20hp across the rev range, as well as a substantial 10-30lbft increase in torque.
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The real story here are the gains after the stock intercoolers get heatsoaked, the stock units simply cannot handle multiple runs on a TT225 with aftermarket software. The performance drop is dramatic, while the TyrolSport UG DSMICs do not lose any power. After five back-to-back runs, The TyrolSport UG DSMICs show gains of more than 40 horsepower and 45lbft of torque in some areas of the dyno!
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We retested just to make verify and the results were duplicated.
We datalogged the most important parameters while on the dyno using VAGCOM to verify the performance results. The first and most important measure is the difference in air intake temperature provided by the stock vs. TyrolSport DSMIC. Here is a chart comparing the first run of each intercooler. As the stock SMIC continues to climb in temperature, the TyrolSport DSMIC flattens out, maintaining less than 50degree Celsius during the entire run. At the peak, the charge air is 20degrees Celsius cooler, which is an excellent improvement.
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The next chart blew us away. By the fifth run, the stock intercoolers were at 70 degrees Celsius even after a one-minute cooldown! The heatsoak on the stock SMICs was incredible, and the difference in power on the dyno can be easily seen in the 50 degree Celsius improvement in air intake temperature provided by the upgraded intercoolers:
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The test car on stock intercoolers even began to overheat towards the end of the 5th dyno pull, even with the dyno fans in place. Given the lack of airflow to the radiator on the TT, please be careful to keep the grills free and clear so that you can maximize airflow to the critical areas in the front of the vehicle. While we did not test against an FMIC as is our usual procedure, the gains over stock were so dramatic, that we did not need any further data to prove that the stock SMICs were wholly inadequate to support even mild modifications on the TT225. Our DSMIC kit will support up to 350whp. If you are going to be producing more than 350whp, we would recommend a large FMIC such as the Precision 600 or 750. Make sure that any intercooler you choose has a bar and plate core, and has data to prove the efficiency. The market has recently been flooded with substandard products, so choosing wisely is important if maximum performance is desired.
Highway Testing
Once our dyno testing was completed, we performed highway data-logging to make sure that the upgraded intercoolers would perform in the “real world”. Again, all of our data was acquired on the same day, in the same exact weather conditions, using the same route of travel. It is always our goal to minimize the variability in testing, to understand the true performance gains(or losses!) of an aftermarket product.
All runs were done in 3rd gear, starting at 2000rpm, and going full throttle to 6500. The car was allowed to decelerate in gear until 2000rpm, at which point we went full throttle to 6500rpm again. This process was repeated until five full throttle runs were completed for each set of intercoolers.
We measured air intake temperature and ignition timing advance.
With air intake temperature there was again an immediate improvement when comparing the first run completed with each set of intercoolers.
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After five runs, the gains were dramatic:
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Ignition timing advance showed an improvement when comparing the first runs:
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And again, big gains in timing advance when the stock units became heatsoaked. As much as 6-8degrees of additional advance at certain points on the curve verify the power gains witnessed on the dyno.
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A word on quality and pricing All TyrolSport products are designed and manufactured in the USA, using US sourced materials. Our commitment to you is to provide the best quality, testing, and support for products that provide TRUE performance benefits for your car. Unfortunately, we cannot compete on price with products manufactured in other countries, given the amount of time and effort we spend on Research & Development. These R&D efforts allow us to bring superior products to market which can only be appreciated by true enthusiasts. We hope you enjoy your car, and our products. Thank you very much, as always, for your support.
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