Make Your Own 2g Intercooler Pipes, Upper S Pipe, Full Upper Pipe, & Turbo Inlet Pipe

First I am going to show you how to make a Turbo Inlet pipe which replaces the "accordian" in your stock 2g intake pipe. This pipe can be bought from Dejontool for $35+shipping or RRE for $40+ shipping. I am going to show you how to make it yourself for ~$9.

Items Needed:

1. Item #81ZX2929P from www.jcwhitney.com $6.69
2. A 2.5" long piece of 2 1/4" ID rubber/coolant hose. Or a silicone coupler if you want to spend more money.
3. 2 Hose clamps, one to clamp the rubber hose to the pipe, the other to clamp the other end of the rubber hose to the turbo inlet.

Step One

You will need to cut 1 13/16" off one end, and 5 9/16" off the other end like shown in the pic, just mark the lines (measure twice, cut once) and cut it with a hacksaw.

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Step Two

Clean up all the edges where you cut with a grinder/sandpaper. Then place the pipe in some warm soapy water, let it soak for ~30 minutes. Then use a scratchpad to take the sticker/glue off the pipe (this will also remove all the metal scraps in and on the pipe since you dont want those getting in your engine).

Step Three

Prime and paint whatever color you want, but I recommend black as it will blend right in with the part of your stock intake pipe you will be using.

Step Four

Install it, here is a pic.

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[98TsiAWD]

I am now going to show you how to make a Upper IC "S" Pipe for ~$13. Dejontool charges $90+shipping for this pipe, theirs replaces the throttle body elbow too, but there is no need to do that, the 2g elbow flows great. This pipe will replace the stock rubber pipe that goes from your upper IC pipe to your throttle body elbow.

Items Needed

1. Item #81ZX2967P from www.jcwhitney.com $8.79
2. 2* 4" long pieces of 2 1/4" ID Rubber/Coolant Hose (2 of them)
3. 2 hose clamps to fit the 2 1/4" Hose, you will use your 2 stock clamps, but will need 2 more.

Step One

Cut 4 3/16" off the end of the pipe, make sure you cut off the "Swaged" end (expanded end). Use a hacksaw for this.

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Step Two

Remove your stock upper S pipe, and put this one in its place, you will notice the other end is too long, you will have to hold it up to your tb elbow and use a permanent marker to mark where you need to cut. This is a trial and error cut, just take your time, you cant put back on what you cut off, so cut a little less of than you think you need to. Then go back and remark again if you need to cut more off. I had to cut 3 times to get mine right. I used a dremel with cut-off disks for mine, used 8 disks to cut it. There is a pic below of mine just to kind of show you how to cut it. (notice I did it the hard way and cut this end before cutting the other end off, dont do it this way)

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Step Three

Now that you have held it in place in the car and made sure it all fits good, Soak the pipe in soapy warm water for 30 minutes. Then use a scratchpad to take the sticker/glue off the pipe and to remove any metal shaving.

Step Four

Prime and paint it any color you want

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Step Five

Install it, just simply use the rubber couplings, clamp half of it onto the pipe you made, and the other half onto the tb elbow. Same thing for the other end of the pipe.
Enjoy.

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[98TsiAWD]

Last but not least, how to make a FULL Upper IC pipe. This goes from your IC all the way to your Throttle Body Elbow. This combo can cost over $200 for a DSM vendor. Make it yourself for ~$20+ whatever your BOV flange of choice cost.

Items Needed

1. Item #81ZX2929P from www.jcwhitney.com $6.69
2. Item #81ZX2967P from www.jcwhitney.com $8.79
3. ~5-7" of 2 1/4" ID Rubber/Coolant Hose
4. 4 Hose clamps
5. BOV Flange of Choice

Step one

Remove your stock upper ic pipes. Insert the 45 degree bent pipe into the 90 degree bend pipe.(only push it in about 1", or else it will cause problems with the BOV flange) Then test fit in the car, the 45 degree bent goes towards the IC, the 90 degree bend towards the T. Body.

The cutting will be trial and error, dont weld the pipes together yet, since you will need to wait until cutting is done so you have them together at the right angle. You shoulnt have to cut much off the 45 degree end of the pipe, but you will have to cut a couple inches off the 90 degree pipe where it meets the tb elbow. This will be an angled cut, just mark with a permanent marker and cut off little by little, you cant put back on what you cut off so take your time.

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Step Two

Drill your hole for your BOV flange, then weld that in place. Once again test fit it in the car so that your BOV is in the correct spot.

Step Three

Weld the pipes together, when you have them in the car aligned how you want it, make a mark across the 2 pipes where they come together so that if you mess it up when removing from the car, you can line it right back up for welding.

Step Four

Clean the pipes all up with soapy warm water and a scratchpad.

Step Five

Prime and Paint your choice of color

Step 6

Install, just simply use a rubber coupling and 2 hose clamps at each end just like any other IC pipe would use.

Here are a few more pics just for referance.

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