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My 4" cold air intake plumbing project.

Since I've seen a couple of people on here looking at solutions for cold air intake piping I though I would share how I did it.

First thing I needed to do was to make sure the turbo was located exactly where I wanted and held firmly in place. So I whipped up a quick turbo support bracket. I used longer studs threaded into the case. Because of this I had to use spacers between the bracket and turbo in order to remove the bracket without removing the studs.

Last edited by nocarrier; 03-16-2014 at 11:51 AM..
Old 03-16-2014, 11:49 AM
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Old 03-16-2014, 11:54 AM
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I really important feature I wanted with the cold air plumbing was a firewall flange. I didn't like the idea of anything finding its way into the engine compartment via the rear tire.

I took a piece of 1/8 6061 sheet and machined it into a nice fitting flange for the 4 inch pipe.



A nice fit.
Old 03-16-2014, 12:01 PM
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I was amazed at how hard the old german steel was. I had a heck of a time making a nice 4" hole.

I like things to be easy to assemble and at the same time east to service when the time comes.

Therefore, I made some threaded bungs and welded them to the flange. This way I don't have to worry about holding a nut and turning a bolt at the same time while bolting the flange to the car.

The notch in the flange is for the original ground lug near the fuse panel. It's a nice welded lug and I wanted to keep it.

Here is a test fit of the flange and the 4" pipe inside.
Old 03-16-2014, 12:11 PM
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I was originally going to use a pre-bent 4" 90 degree bend to fit through the flange but I couldn't get it to fit as tight as I would have liked. So I decided to Pie cut my own 90 degree bend.

I have a great tubing pie cut calculator that works in Microsoft Excel. If anyone wants a copy I'd be happy to share it.

With aluminum welding, fit up is very critical. I was very pleased how this came out.

For those that are wondering, the miter saw in the background is what I used to cull these pieces. I found a really nice blade made by Diablo that is made for non ferrous metals. It does a wonderful job!


Last edited by nocarrier; 03-16-2014 at 12:24 PM..
Old 03-16-2014, 12:22 PM
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For the rest of the piping I used 4" radius pipe.

I used 2 90 degree bends.

The bends coming from the turbo is one 90 degree tube that was cut in the middle at 45 degrees and flipped, rotated and welded at the correct angle.

The other 90 degree was trimmed to meet up with the pie cut tube at the firewall flange.

The trick with cutting mandrel bent tubing is that the cut has to be perpendicular to the tangent of the bend. This way, the cuts don't come out oval and the tubing matches, and stays the same diameter.

To make your cut lines, the simplest way is to make a jig. All you need is a simple plastic protractor (this kind you used back in school) and the dimensions and radius of the bend of your pipe and you can make a simple jig.

I made one similar to this one.

Some guys are good enough to eyeball it. I'm good enough to know that I can't.




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Once I got everything mocked up, I used a magic marker to locate the tubing in the correct orientation and masking tape to hold everything together.

A couple tacks and another trial fit and it's ready to be welded together.

The straight 4" silicone coupler was used so the whole setup can be removed from the car and to help with vibration.

Here is a pic of everything assembled.

Old 03-16-2014, 12:46 PM
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Lastly, here is a picture of the rear of the car right after completion. You can barely make out the 4" air filter as it sits just under the intercooler.

Hope you guys enjoyed my little project and I hope it helps anyone going this similar route.

Old 03-16-2014, 12:53 PM
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A little update I almost forgot.

I replaced the silicone connector to the intercooler inlet with this.

Old 03-16-2014, 12:59 PM
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And that ladies and gentleman is "how its done". Nice work.
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Old 03-16-2014, 01:17 PM
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Very tasty!
Old 03-16-2014, 01:25 PM
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Thanks for the ride up I'm getting ready to embark on the same project glad to see you're using darin's materials really .not looking forward to cutting into my sheet metal but oh well
Old 03-16-2014, 02:31 PM
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Originally Posted by xbmwguy View Post
Thanks for the ride up I'm getting ready to embark on the same project glad to see you're using darin's materials really .not looking forward to cutting into my sheet metal but oh well

My pleasure , I hope it helps with your setup....

I'm the same way when it comes to drilling new holes and usually try and work around existing holes. I actually saved the piece I drilled out. I can't bring myself to throw it away.

Darin's parts are actually very well made. My tubing, silicone, clamps, and the dual seal connectors all came from darin at Race Parts Solutions.
Old 03-16-2014, 05:43 PM
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are your headers the big tube ones from B&b?
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Old 03-16-2014, 10:17 PM
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What kind of hp goal are you shooting for?

I do see a fairly large turbo, 3.2 Carrera intake, 3" IC piping, and a 4" inlet obviously on the turbo.

What heads and cams are you running?

Looks like an easy 600hp build?
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Old 03-17-2014, 10:05 AM
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Thanks for the kind words guys.

Ken, the headers are 1/58 twin scroll from Brian at Rarlyl8.

Tippy, I am shooting for a nice solid reliable 500whp. Here are a few details of my build.

Shuffle pinned case.
Cross drilled crankshaft
Pauter rods
mahle 97mm p/c
Supertec Head studs
Cylinder heads have been ported and polished.
930s (sc) cams
Jerry woods style Mod done to tensioners
Carrera intake with my own version phenolic adapters.
MS3-PRO running full sequential with siemens deka 80lb injectors.
Bosch knock sensor
993 Fuel pressure regulator
Fuel pressure monitored via Honeywell pressure transducer.
GM E85 sensor (I plan on tuning for e85 and regular pump fuel)
Rarlyl8 twin scroll headers
GT3582r Turbo
Bell intercooler
Twin plug edis ignition
Electronic boost control

This is my first efi conversion so I'm still learning a lot as I go. I still need some schooling on setting up my x and y bins on my fuel and timing tables and of course overall efi tuning. It's taking me longer than I hoped but only because I am super anal about understanding every aspect before I move forward.
Old 03-17-2014, 10:30 AM
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If you need my .msq for a reference, let me know.

I know your tables are bigger, but our engines are fairly similar.

Just need to rescale your "req_fuel" from 55lb to 80lb injectors, and the fuel tables will be close enough to drive pretty much immediately.

I read that MSIII has the ability to rescale AE for bigger injectors, so it shouldn't take much AE manipulation too, to get it nicely running.

Let me know.
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Cory - '87 C3.2 (3.4, stock 3.2 heads, cams, intake, with 75mm Mustang TB) Guards/Blk - turbos new to old 1). Borg Warner S366 (66mm comp/73mm turb/0.91 T4 divided ~1.4 bar), 2). Holset HX40 8-blade (58mm/"P" trim 0.84 T4 divided 1.4 bar), 1/4 mile 12.02 @ 129 MPH (street tires), 3). Turbonetics 60-1 HiFi (60mm/"P" trim 0.81 A/R T4 open 1.2 bar), 431whp - MegaSquirt II/EDIS ignition/80lb inj
Old 03-17-2014, 11:02 AM
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500whp?
This ought to do 500whp quite easily!
Nice build.
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Old 03-17-2014, 02:20 PM
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Really stellar workmanship!
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Old 03-17-2014, 02:24 PM
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nocarrier, wow, truly excellent craftsmanship on display - love your attention to detail! I've done a fair amount of fab-work over the years, so can definitely appreciate the time and effort involved - very impressive to say the least!
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