Intercooler piping

[Kruzy]

Everytime I get on the gas the intercooler piping where it connects to the (turbo dump pipe?) keeps blowing off. Now i've tried re-tightning the clamps, and tried buying new alligator clamps and silicone hose but it keeps popping off. Any ideas, can't seem to find answers through the tech areas.

TIA

 

[miller97tsi]

try and push the silicone hose on further than you normally do and get some good clamps and tighten the hell out of it. or try some t-bolts clamps just make sure they are good and tight

 

[DSMN]

Use the kind of piping with the flare on the end they usually dont bolw off. http://www.dsmtuners.com/forums/images/smilies/angry-smiley-032.gif

 

[dsmloverguy90]

http://www.dsmtuners.com/forums/custom-fabrication/324132-homemade-intercooler-pipe-bead-tool.html

that should solve your problem

 

[DSM4me44]

Like the one guy said, use T bolt clamps.

 

[jimmythesaint]

T-bolt clamps and cheap hairspray. Thats all I used and I dont have any beads on any of the piping. Holds great so far up to 28psi. Once I had to remove one and it took me 10 minutes of prying back and forth and jambing a screwdriver around the pipe to break the seal.

Only problem I had was at the turbo exit like you. I readjusted the silicone hose (pushed it a bit more up on the turbo) and used two T-bolt clamps. Zero leaks since.

None of my pipes or hoses leak, but I did manage to blow a weld in the intercooler at around 35psi by accident.

The T-bolt clamps are where its at man. They are a bit expensive but they last longer than regular clamps and seal way better.

 

[dsmcurse]

yeah the ends of the pipes should have a tiny lip or a few tiny (nub jubs as i call'em) welds, you dont have to get crazy and weld a lip all the way around the end of the pipe, just a few evenley spaced little tac welds. take a soft pad on a die grinder and smooth them down a bit. look at the ends of all the factory peices. like the end of the throtle body elbo where the rubber slides over. there are little nub jubs, look at your radiator where the hose goes on. it has small lip. its so the hose clap has something to bite into. hell even the small heater core hook ups have small lip so the clamp will bite. its impportant. pure smooth pipes with no nub jubs will easilly blow apart. yes you can double hose clamp it. but its very ugly, get t-bolt clamps there way better. much more money tho. and the other thing ive found to be the best damn intercooler cuplers is semi truck radiator hose. kinda spendy, but well worth it. go to the local truck shop they'll have 2" 2 1/2" & 3". they should have long peices of straight radiator hose they sell by the inch. this semi truck radiator hose is stiff and stong. im not sure what kind a rubber its built outa but its heavy duty man and the internal threading is 5ply. the other thin is that its black in color. black pipe connectors look good on any engine.

 

[Kruzy]

thanks guys, ill try the T-bolts and hairspray, the pipes are smooth with no nubs, not even flanges for the clamps to lock on. In the mean time I also bought a new fmic because the old one looks a bit on the bad side (bought the car this way). So most things will probably be replaced in the long run.

 

[lnvisiblejon]

t-bolt clamps saved me!

 

[miller97tsi]

tbolts clamps definately helped my piping from blowing off

 

[JStoops]

worm clamps are garbage for holding anything over stock boost.

t-clamps all the way.