DIY Intercooler pipes for MSP

[dmention7]

Once I get these finished, I'll post a how-to, but for now this thread can be a discussion on the project.

So I decided to mock up the piping in 2" PVC pipe before I tried to figure out how to put it together for real. All said and done, it cost me under 10 bucks in materials at Menards (though, I did use it as an excuse to pick up a reciprocating saw ), and about 3 hours. That includes a good chunk of that time spent pulling off those stupid stock plastic pipes, which is a pain in the ass!

Anyways, here's what I came up with:

Hot pipe (turbo to intercooler)



Cold pipe (intercooler to TB)



They both line up almost perfectly, and I was able to get both parts mocked up using only 45 and 90 degree bends, which was one of my goals, since I want to be able to get everything done with off-the-shelf aluminum bends.

Now I have to start shopping for bends and couplers, and probably a small chunk of straight pipe for that straight stretch on the cold pipe. One thing I'll have to keep in mind is that everything from the compressor outlet to the IC outlet is 2.25" OD, but the throttle body is 2.5", so I'll have to work a transition in there somewhere. I'm thinking about using a transition coupler at the IC outlet and making the entire cold pipe 2.5". One other consideration is that at some point I'll have to have a nipple welded onto the cold pipe for the BPV.

I figure that once I factor in the necessary silicone couplers and the custom welding, I'll probably be clocking in around $150-200. So, it's not like I'll be saving tons of cash, but it's something.

So yeah... thoughts or suggestions are welcome. Otherwise I'll post updates as I work on these.

 

[Young Roids]

As long as it doesn't melt and it can hold pressure you should be good.

 

[dmention7]

Oh the PVC is just a mock-up so I didn't have to hack away at spendy aluminum pipes while trying to find the best routing! lol

 

[upgtx]

$200 just for the piping? Jesus Christ, bring it down to Kato and have my buddy Jon Wehner do it. What you spend in gas you will more than make up for in cost.

 

[dmention7]

Well, piping and couplers and shit. Then again, that's all retail price for the bits and pieces... I have yet to see what kind of prices a local shop would be able to give me if I handed them a shopping list.

 

[mndsm]

I say leave the pvc. It's more high tech that way.

 

[Big Nate]

Good work with the PVC Jay. That will make it very easy to fit the real deal.

 

[mazdamn02]

Measure twice, cut once.

 

[DrWebster]

I say leave the pvc. It's more high tech that way.

+1

 

[tricky]

Did you ever end up completing this project?

 

[dmention7]

My pipes and couplers are on order from MAP, and I'll be picking up the materials on saturday!

 

[tricky]

Nice! Is/did MAP do the welding?

 

[dmention7]

Actually, I'm just going with aluminum bends and silicone couplers. No welded bits. Well, I'll probably have to get my BPV nipple welded onto the cold pipe at some point, but I'll worry about that once I get all the pieces cut and fit.

 

[tricky]

Coo, you should get some pics when completed! what'd it end up costing you (if you don't mind me asking) ?

 

[dmention7]

Yeah, once I get everything together I will post a materials list as well as measurements on the individual bends, etc.

All said and done, the materials cost just a tick over $200 including shipping to MAP. I thought that was pretty good considering that the cheapest set out there is about $300.

 

[1fastmsp]

nice work jay, thats a very good idea with the PVC pipes, wish i woulda thought of that on my old set-up. i always make everything, it feels like more of an accomplishment that way, lol even though i did just pick up the corksport FMIC, but you saw my huge SMIC set up last year at porkys and that was all custom built. AWESOME JOB! cant wait to see it finished this summer at porkys.

 

[dmention7]

Thanks for the props man. I'm hoping it goes together as easily once I get the real parts in my hands. And yes, that intercooler you had was freaking massive! lol

 

[dmention7]

Picked up most of my order from MAP today... there were a few couplers that hadn't come in yet, but no biggie. They should be in monday.


oooo a big pile of tubes!

Once I get them all put together, technically they will be a series of tubes. Does that mean my car will be a part of the intarwebs?? (sorry, that was bad.)


And a big pile of couplers... sans 3 2.5" straight couplers that I will be picking up early this week.

 

[dmention7]

FYI, I ordered the following bends:

2x 2.25" 45 degree
2x 2.25" 90 degree
1x 2.5" 45 degree
1x 2.5" 90 degree

My hotpipe will be 2.25" from the turbo to the IC. The coldpipe will start at 2.25", make an immediate bend upwards, and then transition to 2.5" since that's the diameter of the throttle body.

As you can see from the mockup pics, the coldpipe will have a nice long straight section, and that's where I'm going to locate the fitting for the BPV. I have a BPV with 1" inlet/outlet that I picked up from boomergt. I plan to build a custom intake at some point, with a 1" fitting for the BPV return, and I'm hoping that the larger bypass tubing will help eliminate some of the gobble I have right now. And since straight tubing is dirt cheap, it will be easy for me to switch to a different BPV/BOV setup later on, just by having a new fitting welded onto a new chunk of 2.5" tubing and swapping that into my cold pipe.

 

[Jesse MS3GT]

Sounds sweet