Custom Intercooler pipes mock up

[CvicKila02]

Custom Intercooler pipes; Alright guys I’m getting a johnny race car FMIC Core size: 25 wide X 7.75 tall X 2.75 deep. Now I’ve seem many threads on how to make your on pipes with some bends from summit or jegs. My question is I have a friend who works at a shop and can bend exhaust pipes. What I want to do is make a set of mock up pipes so that he can know the angles and just bend them for me. Now he’s not going to have the car so when he makes the bends he has to know exactly what they look like. What I was thinking of doing was taking some material that was cylindrical and about 2.5” in diameter and bending it to the shapes I need so he has a template to go by. Now I don’t know what type of material to use to mock this up. Just wondering if anyone has some ideas of what I could use. Also bring my car to his shop is out of the question his boss won’t allow him to. He has to do it on the side for me. So if I could get something that will hold it’s shape and be about the same size as the pipes he’s making me I’d be all set, and I’m also planning on doing this for my friends 1.8T Gti. If anyone could help me out I would appreciate it. Also what type of material should I use for the pipes Stainless steal or Aluminum?


Thanks
-Dave

 

[anconover]

Is he mandrel bending this tubing? If not i wouldnt bother having him do it. And just look at the car and figure what bends u need. Have them cut with decently long legs and u can cut them to fit later. You should be able to use just 45's 90's, and 180's depending if its short route or side to side etc.

 

[gixrman]

You can use flex-pipe exhuast pipe that you can get from Pepboys or NAPA for cheap. It will hold form once bent.

 

[Thomas91169]

or www.magnumforce.com. i ordered 3 of the 2.5" U bends(6" radius) since you can cut them to make any bend you need. i also got 5 feet of the 2.5" pipe, cost me 90 bucks. mild steel, cause im having my freinds dad weld the j-pipe to IC Inlet all 1 piece, then the IC Outlet to UICP elbow 1 piece, then its going to be powdercoated red, along with my VC and greddy UICP.

and i got a ebay fmic which looks like a great performing IC for 170 bucks, so for around 270 for a FMIC is good shopping in my book.

 

[Mirage2LTurbo]

You can use flex-pipe exhuast pipe that you can get from Pepboys or NAPA for cheap. It will hold form once bent.

Yeah, if you want to make 15lbs at the turbo outlet and 0psi at the throttle body. That shit leaks like none other.

You can find some pics of my IC piping at http://www.kydsm.com/gallery/showgallery.php?cat=509&page=1&sort=20&perpage=12&=

 

[anconover]

i think he means to use to mock it up to know what bends to make..... Most including myself tend to use welding wire etc and play with it, but itll get misformed easily moving around.

 

[CvicKila02]

The only thing is i don't want a bunch of bends with couplers i just want at the most 3 sets up pipes so i was figuring on just making a templete for him and then having him bend it. I'm planning on going with a short route and its a side to side intercooler. I'm just looking for material for a template for him not something that i would actually use on the car like some foam or PVC pipe to make some bends. I just need some idea's on what material is plyable and hard enough to hold a shape so i can bring it to him and say okay this is the exact bends i need bend them to the exact shape. Then i can go back to my car and just drop them in no cutting/ hacking at all almost a professional looking job like SBR or AGP has u guys get what i mean??? I know alot of people out here use 90, 180, and 45 degree bends and some staight pipes to make their own but i think it looks getto and not clean.

 

[CvicKila02]

I was thinking of some kinda of cylindrical foam that is stiff, i dunno i'm just trying to get my ideas rolling guys. I wana mock this up soon.

 

[fishtank]

You should try using flexible aluminum duct that goes on your dryer in your house. Was planning to use that to mock up tubing when i eventually get to that point. Its about the same thickness as what your gonna want your pipes to be so at least you wont have any unforseen clearance issues when the actual pipes are made.

 

[CvicKila02]

That could definatly be a idea i haven't though about yet, but the only thing is that it would loose shape quickly so if i got some "great stuff" the expandable foam and sprayed it into that it would maitain a rigid shape in whatever bend i wanted so that i could give it to my friend with the exact angles. Good idea man Anyone else see i just need some inspiration

 

[CvicKila02]

Does anyone know if PVC pipe when heated bends easly or will it just burst into flames if i use a torch to heat it up a bit??

 

[anconover]

are you serious? if you think your gonna be bending plastic tubing with a torch or somethin ur outta ur mind

look at pics of people with side to side intercoolers and just see what bends they use and how many. then cut to fit as u need. if he isnt mandrel bending this then ur gonna have some serious nasty kinks in the bends around the front...

 

[CvicKila02]

Yea i think its going to be press bent so there would be some ridges in it, should i be concered with that? I didn't think that it would be a huge hp loss with some turbulance in the pipes. I know that you want to keep it as smooth as possible.

 

[anconover]

i wouldnt pressbend it. especially not when your going to need 180* bends.

 

[CvicKila02]

So does anyone have like a parts list of what types of mandrel bent pipes i should pick up and how to peice it together if everyone says that press bent wouldn't be the best option?? I'm just really worried about buying a ton of mandrel bent bends and not using them therefore wasting my money, and not having it work right. Cause i've done a few mods in the past to try and save money, but in the long run i end up spending more money.

 

[Defiant]

Does anyone know if PVC pipe when heated bends easly or will it just burst into flames if i use a torch to heat it up a bit??

It'll show you what happens when you try to bend tubing without a mandrel.

 

[CvicKila02]

Okay so i get that press bent pipes will: a) kill the smooth flow of air b) will decrease the inner diameter of the pipe. So now that i have learned that this is not a good way to do IC pipes what pipe bends would you recomend buying for this intercooler. I have searched and found that no one has and exact list of what you will need they just list the angles of the maderal bent peices. Thanks

 

[anconover]

youll probly need like 2 180's, 2 90's, 1 45 maybe. thats if ur using an existing tbody elbow. and maybe some straight tubing. off the top of my head. just look at it man u should be able to tell what u need.

 

[CvicKila02]

Thanks for the response guys, I'm going to try out building the pipes on my friends GTi first i'll learn from the mistakes i make with his money . As for Couplers i have to search around for some radiator hose to use. Thanks alot. Anyone eles have any comments please feel free to help me out thanks.

 

[rowlex]

use PCV piping or ABS piping from lowe's/home depot if you use the ABS pipe and seal it right you can even use it temporarily.

 

[kevingst]

Look at my post on the johnny racecar thread to see how I did my pipes. I think it's post #741 or something like that. http://www.dsmtuners.com/forums/showthread.php?p=1406165#post1406165

 

[Lunch_Box]

Does anyone know if PVC pipe when heated bends easly or will it just burst into flames if i use a torch to heat it up a bit??

It can be done but it requires special machines and the bends wont be as tight as you need.

 

[Zexell]

how would a BOV be put on custom piping?? And if this is possible, cant you just buy accord cold air intakes off ebay and just chop them up for UICP??

 

[arash15]

how would a BOV be put on custom piping?? And if this is possible, cant you just buy accord cold air intakes off ebay and just chop them up for UICP??

its easy to put a BOV on cutom piping. 1. get the flange, and drill a hole in the ic pipe and then weld the flange on the pipe. the accord cold air is an option but thats pretty ghetto. you could prpbaly go to a muffler shop and theyd be able to work with you better

 

[PSI TSI]

The only thing is i don't want a bunch of bends with couplers i just want at the most 3 sets up pipes so i was figuring on just making a templete for him and then having him bend it. I'm planning on going with a short route and its a side to side intercooler. I'm just looking for material for a template for him not something that i would actually use on the car like some foam or PVC pipe to make some bends. I just need some idea's on what material is plyable and hard enough to hold a shape so i can bring it to him and say okay this is the exact bends i need bend them to the exact shape. Then i can go back to my car and just drop them in no cutting/ hacking at all almost a professional looking job like SBR or AGP has u guys get what i mean??? I know alot of people out here use 90, 180, and 45 degree bends and some staight pipes to make their own but i think it looks getto and not clean.

How could spending all that time and money on welded up madrel bends be more Ghetto than spending 50bux at an exhaust shop getting kink bends? I think it just looks custom.