DIY intercooler hoses $100 + turbo inlet hose

flash7210 · **Posted:** Mon Jan 30, 2017 6:08 pm

BLUF:
It's a lotta work but these can be assembled for under $100.

flash7210 · **Posted:** Mon Jan 30, 2017 7:54 pm

I already had the weeks intake elbow kit (sasquatchparts.com) so I removed the elbow and kept the intake flange. The drivers side tube was the most difficult.
Parts list for drivers side:
2.25-2.5 inch 90 deg reducer elbow
2.5 inch diameter aluminum pipe, 45 deg bend, 24 inches long
2.5-2.75 inch reducer straight
4 hose clamps

The passenger side was easy.
Parts list for passenger side:
2.0 inch 90 deg elbow
2.0 inch diameter aluminum pipe, 45 deg bend, 24 inches long
2.0 inch 45 deg elbow
4 hose clamps

I used a 5 inch fiber disk chop saw for cutting the aluminum pipe.
All parts an pieces can be ordered from http://www.siliconeintakes.com/
I ordered all my pieces from sellers on ebay and amazon which was a little bit less.

PZKW108 · **Joined:** Sun Apr 06, 2014 5:23 pm **Posts:** 461

WOW really nice job !!!!

I've been thinking about that for a while

You should sell a kit !!!

flash7210 · **Posted:** Mon Jan 30, 2017 8:20 pm

A couple of tips:

Given that the outlet from the intercooler is 2.75" and the weeks intake flange is 2.25," there are several ways you could assemble the drivers side tube. If I had to do over again, I would use:
2.25-2.75 90 deg reducer elbow
2.75 aluminum pipe, 45 deg bend, 24 inches long
2.75 "hump hose" for more flexibility

When cutting the aluminum pipe, measure carefully and cut a little bit too long. If a little bit too short, or even just right, there is a chance the parts could pop off under high boost.
This can make assembly kinda difficult because the aluminum pipe is not flexible.

Oh, and its helpful to remove the battery and remove the cables from the front fuse box. Then unclip and push the fusebox aside.

WWDiesel · **Posted:** Mon Jan 30, 2017 10:26 pm

They look really nice and I am sure they function very well; but what is the advantage over a good set of silicone boost hoses??? :roll:

And all those extra connections and hose clamps seems somewhat counter productive... :shock:

flash7210 · **Posted:** Mon Jan 30, 2017 11:17 pm

WWDiesel wrote:

They look really nice and I am sure they function very well; but what is the advantage over a good set of silicone boost hoses??? :roll:

And all those extra connections and hose clamps seems somewhat counter productive... :shock:

The only real advantage is cost.
But it also a lot more work.

Buying a set of samcos or whatever and installing them is easy. Whats the fun in that? :lol:

The silicone elbows and adapter and hose clamps are currently holding at 20psi. Haven't popped a tube loose yet :BANANA:

Ceearedeedriver · **Joined:** Fri May 06, 2016 8:44 pm **Posts:** 177

flash7210 wrote:

WWDiesel wrote:

Buying a set of samcos or whatever and installing them is easy. Whats the fun in that? :lol:

Agreed, I make and repair a lot of stuff purely for the challenge and entertainment when it would probably be more logical just to throw some money at it.

Now, did you bead the ends of these aluminum pipes or are you just hoping the hoses will stay in place?

Nice work BTW.

flash7210 · **Posted:** Tue Jan 31, 2017 9:09 am

Ceearedeedriver wrote:

flash7210 wrote:

WWDiesel wrote:

Buying a set of samcos or whatever and installing them is easy. Whats the fun in that? :lol:

Agreed, I make and repair a lot of stuff purely for the challenge and entertainment when it would probably be more logical just to throw some money at it.

Now, did you bead the ends of these aluminum pipes or are you just hoping the hoses will stay in place?

Nice work BTW.

This was all done at home in my driveway with the limited tools I have. I dont have the ability to bead the ends.
Which is why I cut the aluminum pipe a little bit too long, giving them less room to wiggle apart. But this also makes them harder to assemble.
The angles on the drivers side are not exactly right, which puts the 90deg silicone intake elbow under a bit of tension. If anything were to pop apart, thats where it would be.
And it did pop apart on my first test drive. But I re-seated the pipe and elbow and made double sure the clamps were tight.
So far, its holding.

WWDiesel · **Posted:** Tue Jan 31, 2017 10:54 am

flash7210 wrote:

This was all done at home in my driveway with the limited tools I have. I dont have the ability to bead the ends.
Which is why I cut the aluminum pipe a little bit too long, giving them less room to wiggle apart. But this also makes them harder to assemble.
The angles on the drivers side are not exactly right, which puts the 90deg silicone intake elbow under a bit of tension. If anything were to pop apart, thats where it would be.
And it did pop apart on my first test drive. But I re-seated the pipe and elbow and made double sure the clamps were tight.
So far, its holding.

A little trick I will share I learned on my Dodge Cummins that is running 40+ psig boost;
I sprayed the ends of the metal pipes with 3M™ Hi-Tack 76 Spray Adhesive before sliding the silicone hose pipe connectors on the pipes and then clamped them.
Have not had a single connection come loose or blow apart since I did this and upgraded to the heavy duty silicone connectors and spring loaded "T" bar clamps. :BANANA:

Before I did this I was constantly blowing apart a couple of the OEM metal hose connectors.... :banghead:

That 3M spray is some very good stuff!!!

racertracer · **Posted:** Tue Jan 31, 2017 8:29 pm

Hello Flash,

Could you also share info on your air filter setup?

Thank you

flash7210 · **Posted:** Tue Jan 31, 2017 8:41 pm

racertracer wrote:

Hello Flash,

Could you also share info on your air filter setup?

Thank you

2.25-2.5 silicone 90deg reducer elbow
Short piece of 2.5 inch aluminum pipe
2.5-3.0 silicone 90deg reducer elbow
Short piece of 3.0 inch aluminum pipe
Conical filter for 3.0 inch intake
Note: my setup has no provision for a CCV hose, EHM only. I plan to fix this in the near future.

The air filter inlet can be done several ways. The important part is that the turbo inlet is 2.25 inch.
Just assemble whatever conbination of of elbow sizes will fit to you chosen air filter.

GordnadoCRD · **Posted:** Tue Jan 31, 2017 11:23 pm

Very nice Flash!

More bling to keep polished!

mass-hole · **Posted:** Thu Feb 02, 2017 1:06 pm

WWDiesel wrote:

They look really nice and I am sure they function very well; but what is the advantage over a good set of silicone boost hoses??? :roll:

And all those extra connections and hose clamps seems somewhat counter productive... :shock:

Less expansion under boost too. I have had my wife power brake and watched my mishimoto hoses expand quite a bit.

flash7210 · **Posted:** Sun Feb 12, 2017 3:07 pm

Siliconeintakes.com has what they call a silicone port system. Its what I used to attach the ccv hose to my turbo inlet (no more EHM).
You will have to cut hole in the silicone elbow to make it fit.
In the past I have recommended not doing the conical filter thing because it draws in too much hot air from under the hood, making IAT kinda high.
But so far this setup seems to be working quite well.
If IAT gets too high come summer time, maybe I will make some sort of heat shield.

Turbo inlet hose

PZKW108 · **Joined:** Sun Apr 06, 2014 5:23 pm **Posts:** 461

flash7210 wrote:

Siliconeintakes.com has what they call a silicone port system. Its what I used to attach the ccv hose to my turbo inlet (no more EHM).
You will have to cut hole in the silicone elbow to make it fit.
In the past I have recommended not doing the conical filter thing because it draws in too much hot air from under the hood, making IAT kinda high.
But so far this setup seems to be working quite well.
If IAT gets too high come summer time, maybe I will make some sort of heat shield.

Turbo inlet hose

I have pretty much the same setup, same air cleaner , provent at the same location !!!

I will try to upload a picture !!

flash7210 · **Posted:** Sun Apr 02, 2017 6:36 pm

Loaded a Yeti stage 4 hot tune and turned up the boost.
Everything held together at 27psi.

DIY intercooler hoses $100 + turbo inlet hose

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