hi guys and girls

im going to be clocking my turbo but i need to get an intercooler pipe made up for the hot side of the turbo to intercooler, i was speaking to my friend at the garage and he cant weld ally but he did say he could make me one from steel im just wondering what everyones views are on this?

thanks in advance

si

I/C pipe in steel? I'm sure it would work but it adds weight up high at the front of the car where you really don't need it AND it will probably go rusty in no time.......unless you do it in SS:-P. If it were me I'd get it done in ally. Take a drive to see Bob Hall at Concept Racing, Ross-on-Wye. He's great for stuff like that, or there may be someone more local who could point you in the right direction. Merlin, Castle Combe?

_________________
Don
GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

No to steel, yes to aluminium and stainless steel...

_________________
Kris
95 ST205 - slept for 10 years, now waking up...
Avensis
http://www.gtfours.co.uk
_______________________________________
Turbocharging - the replacement for displacement

sorry i ment s/s like what they use for exhausts lol

I would ask your mate what he is welding the stainless with.

You can weld stainelss with standard MIG & regular welding wire but the weld rusts.

_________________
JP
GT4DC Treasurer

Grey St185 RC
Silver BMW E46 M3
Multicolour yawn Honda VFR400
Silver Honda Civic Type-R

Ah right he's welding it with a mig welder, so I'm guessing it's going to turn into a rusty mess?

James at JDModified (formerly TGT) does some VERY NICE piping

_________________
Vice Chairman
1990 White UK Celica ST185 - Project DTM
1997 Cream BMW R1200C (as seen in James Bond "Tomorrow Never Dies")
2005 Jaguar X-type 3.0 Sovereign AWD Automatic
Blood Bikes - https://www.freewheelers.org.uk/

Yeah the thing is I'm doing the work then I've got to try and get the car to them so they can make me some pipes

Hi Dude,

What i did was,

i got all my pipes and bends.
Then i mocked them up and cut them to size so each join was spot on.

i then used those cheep crap rubber (pretend silicone) joiners and jubilee clips to fasten the lot together...

oh yeah i cut 2 oblong slots on each joiner amd also marked each pipe with a marker pen and ruler from one pipe to the other across the joiner for reference.

when i was happy with it i took it allong to my local welder who did the rest.

before welding



After



on the car

_________________
1990 JDM ST185 Grey.
ST205 head gasket.
ARP head bolts.
ST205 Koyo Rad. (almost)
Front mount intercooler.
Colder plugs.
3" decat pipe.
4 Branch manifold.
Nitrous Oxide Steroids for Cars!

Thanks for that midnite i think thats what im going to have to do! i just want to get rid off all the samco joins

My hard pipes are in 3 sections:-

From the turbo to the intercooler is one piece
From the intercooler into the engine bay is the second piece
The third piece runs upto the throttle body.

I have:- 5 joiners in total.

1 Samco join at the Turbo outlet
1 Samco Join at the Intercooler inlet
1 Samco join at the intercooler Outlet
1 Samco Join at the Throttle Body

As the run from Intercooler outlet to throttle body is the longest i joined these 2 pipes half way so it can:-

A) flex with engine movement.
B) Be removed in sections for access when working.

I made a tool out of some old mole grips, a large washer and the u part of a heavy duty exhaust clamp. I welded the U onto the bottom Jaw and the washer to the top jaw. Then using them with the washer inside the pipe where the joiners fit i was able to work a swage onto the ends of the pipe for clamping.

Mind you i used ally tube.

_________________
1990 JDM ST185 Grey.
ST205 head gasket.
ARP head bolts.
ST205 Koyo Rad. (almost)
Front mount intercooler.
Colder plugs.
3" decat pipe.
4 Branch manifold.
Nitrous Oxide Steroids for Cars!

Midnite - I like! Great idea!

_________________
Kris
95 ST205 - slept for 10 years, now waking up...
Avensis
http://www.gtfours.co.uk
_______________________________________
Turbocharging - the replacement for displacement

Yep, swaging or rolling the pipe ends is essential if you are to avoid blowing the Samco joins. I've witnessed this on other peoples cars and its virtually guaranteed to happen on a trackday. Even Mikalor clamps are not strong enough to hold the joins together under turbo boost pressure.

_________________
Don
GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

The tool looks a bit gash but it worked, i didn't need it to super time efficient or to stand up to mass production wear and tear.

i used it for my 5 pipe ends i had to buy a n extra 90 bend for my set up and cut it however it was already had swaging.

it did mark the ally a bit so next time i'd use some kind of padding but you can't see it... its inside the samco lol

_________________
1990 JDM ST185 Grey.
ST205 head gasket.
ARP head bolts.
ST205 Koyo Rad. (almost)
Front mount intercooler.
Colder plugs.
3" decat pipe.
4 Branch manifold.
Nitrous Oxide Steroids for Cars!