are made from 2" inside diameter aluminum tubing (a little over 2.3" outside
diameter). I used a hydraulic pipe bender for the long bends, for the short bends, I
had to cut angled pieces of the pipe, then weld together the pieces to make the
bends. I then ported out the insides of the short radius turns so they were smooth
and rounded. Each short radius turn is made up of about 5 "wedges" welded
together. There are 2 short radius turns in the pipes, the first one comes out of the
turbo compressor output port, the other is directly before the throttle body. Below
are pictures of the pipes after they have been finish ground and polished (by
hand...lots of elbow grease). The blue tubing is 4 layer silicone hose, made
specifically for holding the pressures a turbo charger can create (those 3 tube pieces
were almost $60 alone)
first time with the intercooler. Nothing bad occured durring the test run. I let the engine
idle for 15 minutes and let the fan cycle on 3 times to be sure it was fully up to running
temperature. I don't have any kind of temperature probe or anything, but by touch, the
turbo output tube was pretty hot (about as hot as the bottom of a fresh pizza box, so
probably 125 degrees or so. The hot side of the intercooler was relatively warm, maybe
90 degrees (the hood was open durring this test, so the turbo output tube was obviously
cooling some by its self), and the intercooler output side was cold to the touch, maybe
65 degrees.....in other words, this is a huge success. Unfortunately, I don't have the car
drivable because the body work isn't done, so I had to resist taking it for a drive. The
pictures below are right after the first run.
comparison (so those not knowing can see what has been
done)
