long neck IC - how to connect BOV?

[Falk930]

Just received my RUF IC from pelican member im4duke,
thank you for great part!

Its a long neck IC, I removed this intermediate casting
which includes the BOV/bypass valve.
No problem for me to build the connection from the
air meter to the turbo inlet with BOV connection.

But, how do I connect the BOV to the IC,
I guess I use the 965 one,
the IC has no connection for this.

I am sure you can recommend something

Falk

[rsrmike]

Can you post some pictures of the intercooler?

This may sound like butchering, but you could use a brass fitting w/ barbs on one end for the hose connection, and pipe thread on the other end that would screw into a hole made in the intercooler, provided the intercooler tank is a thick cast aluminum piece...

[turbobrat930]

You need the big rubber elbow (965 part number) that connects the lower CIS system to the intake for the turbo. You will also need the small black "recirculating" valve that plugs into the rubber elbow. You will need to cut a small hole into the side of the I/C and then braze a fitting onto the I/C. Then connect the "recirculating" valve to the brazed fitting via a reinforced hose. The valve also needs a boost line attatched, and routed to a boost source. ( Could also be from the I/C)

[BoxxerSix]

There are a handful of way to go about doing what you need to do, just do it right(properly I should say)

You can either do it similar to the 965 route and have a 1" aluminum tube welded to the throttle body side endtank of the IC which allows you to hook up the OEM bosch style recirculation valve to the system and plumb back into the intake track post CIS/pre turbo

Another option is to purchase an after market recirculation style valve, like a Synapse Engineering Syncronic, and have the appropriate adapter fitting welded to the intercooler endtank(again TB side for more clearance). You can then reroute from the valve outlet back to the said position on the inlet track.

While the "brass fitting" technique would work, it's a mess and failure prone thing to do. And an awful thing to do to a RUF part as well

[turbobrat930]

Adam, I agree. That is what I actually ment when I posted the response. Get an AL tube, weld it to the I/C.... when I said braze, I did not mean to imply a brass fitting.

[BoxxerSix]

Originally Posted by turbobrat930

Adam, I agree. That is what I actually ment when I posted the response. Get an AL tube, weld it to the I/C.... when I said braze, I did not mean to imply a brass fitting.

Sorry, I was referring to the post above yours when I said "brass fitting technique"

[Falk930]

Thank you for suggestions.

I am wondering how this was solved from RUF
when they installed their IC.
Had they used a open BOV?
Or where did they connect the BOV?

Maybe someone with a RUF IC setup
can post some pictures?

Falk

[rsrmike]

Originally Posted by BoxxerSix

While the "brass fitting" technique would work, it's a mess and failure prone thing to do. And an awful thing to do to a RUF part as well

Agreed the 1" aluminum tube welded in is the best idea, I should have mentioned that first.

However, If the intercooler tanks are thick cast aluminum, there is no harm in using a "pipe fitting" I don't see how that is a mess, or an "awful thing to do to a RUF part"

One could argue that the fitting might fall out due to thermal expansion, or stripped threads, but if done right, excuse me, properly it won't.

An aluminum tube in the wrong hands of an incopetent welder is likely to make just as big a mess if not more. Also, no one mentioned using a bead roller to keep the hose from blowing off, would that not cause as much damage as a fitting failure?

Either way you are still hacking up a RUF part to make it fit an application, the guy asked for suggestions to get his car running and I gave him one that was easily attainable, who knows how much trouble it may be for him to find a TIG welder to do it properly.

I'm surprised there is no place to connect a bypass valve if it truly is a "longneck" intercooler, although I don't recall seeing any on Steve Beddor's 964 based CTR back when I had the joy of doing some minor work on it (for the second owner). I guess that's why the turbo's sounded so wicked when I lifted off the throttle.

I knew I might catch hell for mentioning that idea, hence the "butchering" comment at the very beginning. I would also like to see pictures...

FALK: Good luck on your quest, if you do have a tube welded on, be sure you have a "bead" rolled on first or you will likely be no better off than my "awful" idea...

[BoxxerSix]

Sorry Mike, never meant to rag on you like that. Just stating that if it's going to be done at all it should be done correctly from the get go(IE have a competent fabricator perform the work to the intercooler).

Then again on the flip side of things like you mentioned, you'd think RUF would have built the IC for a BPV from the start. Their components are certainly not cheap and you'd probably expect certain things to be there

Regards,

[OSI930]

Have you looked at this thread?:
Andial Problem
Post # 38 starts a discussion regarding Ruf intercooler installation.

[rsrmike]

I'm sorry too Adam,

I shouldn't have been a condescending prick. You were absolutely right in your advice. I will admit to letting my emotions affect my judgement this morning. I woke up mad at the world due to outside circumstances. That's no excuse, I'm sorry I took it out on you and exposed the rest of the people here to it as well. The lack of such behavior is the one of the very reasons I frequent this board. There is too much of that on the internet and I'm amshamed I brought more of it here.

I know you're a talented fabricator, I hate to admit I am not. Thanks for being the bigger dude and not propagating a pissing contest

Hopefully those pics from the other thread will help as well, thanks OSI

[Falk930]

Originally Posted by OSI930

Have you looked at this thread?:
Andial Problem
Post # 38 starts a discussion regarding Ruf intercooler installation.

Thanks, very helpfull!
I was looking for something bigger to connect the BOV to the IC.
But it seems they use the small tubes on ICs right side.
Fine.

Interesting, it seems RUF made different ICs.
I will post a pic to compare.

Thanks so far!

Falk

[Craig 930 RS]

This help? An idea from my 930:

[NathanUK]

Craigs 930

[WERK I]

Anywhere between the compressor outlet and top of throttle body is fine. Have you considered using the downtube between IC and turbo?

[Falk930]

Thanks for help,

I have seen the small intercooler connections before.
Just was thinking these 20mm`s are a little small.
I will do it that way.

should I leave the decell valve away?

thanks!
Falk

[NathanUK]

The Bosch 964t bypass valve is only around 20mm anyway.