Fabricating a C2 Turbo to intercooler pipe

sand_man · 09-12-2007, 06:23 AM

So I've bought a factory C2 Turbo intercooler to replace my B&B short-neck. I'm already running the C2 bypass valve (I rendered the large BOV housing in-operable), so this is the final step in liberating myself from yet another enormous overbuilt factory assembly.

I'm hoping to have the intercooler this Friday to take some measurements and test fit.

The factory C2 compressor hose that connects the turbo to the intercooler is over $300 new. I found a used one from DC Auto for $244.

I'm really thinking it would be straight forward to make one. There are sooo many high temperature silicone hose options available these days: elbows, couplers, hump hoses, reduces, angles, etc. So I'm thinking there are plenty of available options to make a damn fine piece.

Here's my question: Should I try to make the entire hose from high temp, high pressure silicone or should I just use some silicone couplings in conjunction with a standard metal pipe? For example, metal pipe in the middle connected to the turbo and intercooler with silicone couplings.

The reason for my question is that silicone really isn't resistant to fuel and oil. So I'm afraid that the thin oily film that's always around the intake track will eventually ruin the silicone hose. It's easier and cheaper to replace just the end couplings rather than an entire silicone hose.

Any thoughts from the world famous Pelican fabricators?

sand_man · 09-12-2007, 06:46 AM

One other tid-bit of info to consider: I'm on Electromotive XDi ignition, so I don't have to worry about clearing the distributor...

David · David's Garage

After making one for my car, $300 for the factory piece sound like a deal. It'll also flow better than anything you could make.

sand_man · 09-12-2007, 11:09 AM

Quote:

Originally Posted by 125shifter

After making one for my car, $300 for the factory piece sound like a deal. It'll also flow better than anything you could make.

I understand what you're saying. Beyond the taper that the factory pipe has - which could have an impact on flow - I just don't see how it would require much fabrication.

Not mine:

sand_man · 09-12-2007, 11:14 AM

I wonder how critcal the taper really is??? Most turbo to intecooler plumbing that I've seen uses straight tubes...of course there's nothing quite like an aircooled Porsche Turbo...

quattrorunner · quattrorunner's Garage

Check evilbay for couplers and reducers and stuff pipes,

sand_man · 09-12-2007, 11:35 AM

Quote:

Originally Posted by quattrorunner

Check evilbay for couplers and reducers and stuff pipes,

Thanks, for the tip! Yes, I've already got sources lined up and a pretty good idea of what I'll need. Just not sure if I'll make the entire pipe from silicone hose or if I 'll adapt a metal tube for the center section with silcone couplers on the ends.

I just thought I'd throw it out there and get some feedback.

Porschephd · 09-12-2007, 01:14 PM

We just build them and use couplers when we need to. This one was to clear the dist and the new turbo.

sand_man · 09-12-2007, 01:28 PM

Thanks, good Doctor! Yep, I've got that one saved to my library from the original thread on Rennlist that you posted it on! Love that car, and love what your shop did with it! A+...

Porschephd · 09-12-2007, 07:01 PM

Thank you sir. That car about killed me. It has been a very long project and to click off those numbers made all of it worth while. For me and for the customer. The EFI stuff is all my baby and I do it from start to finish. So it is a lot when you consider ALL the things I do in a day.

AngM018 · 09-12-2007, 08:58 PM

Good to see you finally took the plunge into the C2 intercooler realm! I know you have been talking about this ever since the holiday party back in January.

Let me know when you have it installed. I am finally getting to the cam timing stage and could use your help. Plus I want to check out this intercooler.

P.S. make sure your car is really loud when you come over. My neighbor is getting on my nerves again, and I need something for her to really complain about!

sand_man · 09-13-2007, 06:01 AM

Quote:

Originally Posted by AngM018

Good to see you finally took the plunge into the C2 intercooler realm! I know you have been talking about this ever since the holiday party back in January.

Let me know when you have it installed. I am finally getting to the cam timing stage and could use your help. Plus I want to check out this intercooler.

P.S. make sure your car is really loud when you come over. My neighbor is getting on my nerves again, and I need something for her to really complain about!

Hey John...sounds like you've made good progress on your engine! I'm booked solid this week with work and family obligations, but should have some time next week to stop buy and lend a hand.

I love my B&B intercooler and am convinced that it's an excellent performer...all that anyone would ever need for a street car. As for the C2 intercooler, it's more of an aesthetic thing for me. I just love the design and love that it's a factory part. It took a while to find one that fit my criteria.

As for my question in this thread about making the boost pipe, I looked around my garage last night and spotted an interesting piece of pipe that just might have the correct bend. That's all I'll say for now other than this piece of pipe will need to be cut from a collection of other pipes that were once part of an expensive assembly that broke

AngM018 · 09-13-2007, 10:08 AM

Quote:

Originally Posted by sand_man

Hey John...sounds like you've made good progress on your engine! I'm booked solid this week with work and family obligations, but should have some time next week to stop buy and lend a hand.

I love my B&B intercooler and am convinced that it's an excellent performer...all that anyone would ever need for a street car. As for the C2 intercooler, it's more of an aesthetic thing for me. I just love the design and love that it's a factory part. It took a while to find one that fit my criteria.

As for my question in this thread about making the boost pipe, I looked around my garage last night and spotted an interesting piece of pipe that just might have the correct bend. That's all I'll say for now other than this piece of pipe will need to be cut from a collection of other pipes that were once part of an expensive assembly that broke

Sounds good, I have a bunch of other projects I need to do in order to get the car road worthy. This will give me a chance to get them all done. Let me know what day works for you, and your favorite beer.

sand_man · 11:31 AM

Well the factory C2 Turbo intercooler was just delivered!!! Holy smokes this thing is HUGE!!! I'm amazed at how what Porsche tried to label an "intercooler" (charge air cooler) on the 930, evolved into this monster! Ain't technological advancements grand?

I really think this is all I'll ever need in an intercooler. My B&B works fantastic, but I don't plan on ever running a tail condenser for the AC, so it looks strange to keep such a square intercooler, like the B&B.

So now the fun begins: cleaning it up and figuring out how to fit the damn thing. The one I bought has been taped up and put in storage for years, so it needs a little TLC before I can actually fit it.

More to follow...

BReyes · BReyes's Garage

Good to see you are having fun!

I have received my TT intercooler recently and I have been thinking about how much fun it is going to be to get it plumbed properly, and with the proper brackets as well.

When I last visited with Marco at Billet Design in Boca Raton, he was building some plumbing for some (unrelated trick) applications and the pipe he was fabricating was including a raised lip on the ends to strengthen it. It is one of the small details I have been considering. If not going with the factory item have you thought about speeking with Billet design for input.

Regards,

sand_man · 09-18-2007, 07:41 AM

Thanks for the input, Bernard. I've been studying the C2 intercooler for some time. This pipe that connects the turbo to the IC really isn't that long. You can clearly see it in the picture further up in this thread.

Just today, I ordered a few different silicone couplers and pipe reducers (in stealthy black), even one with a 45 degree elbow. I ordered a few variations just to provide some options...I'll return what I don't use.

I think by using a "hump hose" coupler at either or both ends, which allows up to about 20 degrees of movement, I should have enough play to fit the pipe that I've chosen. This piece of pipe that I have, also has a nice mandrel bend in it that I could use if I needed some additional angle.

As for the IC, I started cleaning it up last night. I have a few ports that I'll need to plug up on it, and I'll probably hit it with a coat of black wrinkle finish paint...all in all, it should clean up nicely.

sand_man · 09-18-2007, 08:01 AM

A few pictures of what I ordered. This will be used in conjunction with the 2" pipe I have yet to cut up:
3" to 2" Reducer - the large end attaches to the IC:

2" hump hose connector - attaches to the turbo charger neck:

3" to 2" reducer with a 45 bend - ordered this one just in case:

The rest will be the polished stainless pipe in between the couplers above.

E-man930 · 09-18-2007, 11:13 AM

Sandman,
I have most of the factory parts (NIB) you may need to mount the intercooler to the engine. send me an email or PM and I'll discuss what I have if you are interested.
I like your idea rather than going with a $300 factory hose that costs $3...

E-man

sand_man · 09-18-2007, 11:24 AM

Quote:

Originally Posted by E-man930

Sandman,
I have most of the factory parts (NIB) you may need to mount the intercooler to the engine. send me an email or PM and I'll discuss what I have if you are interested.
I like your idea rather than going with a $300 factory hose that costs $3...

E-man

Thanks E-man! Funny, I have pictures of the C2 intercooler that you had for sale a while back! After seeing it then, I had to have one...they just don't come up very often (I think this one was yours):

mdurbahn · 09-18-2007, 05:34 PM

whoa that is huuuuuge. i like it