How is this possible...
 

I've had two inter cooler o rings blow out recently... I don't even know how it's possible for 1/2 the o ring to end up outside the piping assembly. The inter cooler is bolted firmly in place, so no movement there. Only running 1 bar boost. Anyone else experience this?http://forums.pelicanparts.com/uploa...1533771214.JPG
http://forums.pelicanparts.com/uploa...1533771214.JPG

did you try adding one of these too https://www.pelicanparts.com/cgi-bin/ksearch/PEL_search_2016.cgi?command=DWsearch&description=i ntercooler+seal

cool product... but more than 10 yrs of ownership and many smiles, and this hasn't been a problem before. :confused:

Hi Phillip
I put a silicone hose over the connection point, with 2 hose clamps. I'll send you pic.

Hey Phillip,

Is that O ring hollow? looks that way in the pic.

Is there a chance that there is a lot of clearance in the tube that the intercooler fits into?
Otherwise my bet is the intercooler is lifting out of the tube, at 1 bar there is a lot of pushing force there. About 100lbs push at 1 bar. How quick is your blow off valve?

It happens to everyone at some point. My theory is that the o'ring material over time gets softened by the heat and possibly oil mist (all turbos spit a little oil past the seals, dependent upon their age). Once soft enough, they can deform out of position when on boost. Put their replacement on your scheduled PM list.

I like the idea of adding a silicone coupler but, with T-clamps as opposed to standard hose clamps.

No burrs in the land?

Hey Rod, no, O ring is not hollow... it's one from Pelican, it's only a couple of weeks old at the most. I can hardly push the boost pipe on to the inter cooler it's so tight, even with a bit of lube. no play what so ever. There is a small bit of miss alignment once its hooked up though, as you can see in the pic. No way the inter cooler can lift, as you can see all the supports/bolt down connections...

nope...

O rings are designed to take around 1500 PSI before needing reinforcement, so beings you’re 1/100th of that, it’s tearing from movement.

maybe that o ring was made on a Monday.
A little silicone divers grease works good on them.

Hmmm, how is the other end of that up tube connected to your GT35? Silicone hose? Is there any chance of movement there or the turbo mount flexing?

Have had the same problem and I suspect the hose between the turbo and the up tube is bulging under boost shortening the assembly. The o-ring is then free to escape...

I had an intermittent problem with intercooler seals until I added one of these^^^^, no problem since.

i put a little grease on them to help the slide in. I have torn one putting the IC back on.
buy extras if you take it on and off a lot.

I wouldn’t be surprised if its a quality issue. I recently had a oil return tube o ring failure on my 3.0 liter race car. Engine was professionally built about 2 years ago. The o ring just split open and started dumping oil on the headers.

It can't be moving on the turbo end, and the support is big enough.... has to be in the silicon coupler I'm usinghttp://forums.pelicanparts.com/uploa...1533816435.JPG

Hey there Philip,

From your first photo, you can clearly see that the 2 parts are moving around a lot. The blemishes and burnishing marks clearly indicate that the 2 tubes are rubbing and moving around.
It's got to be your hose off the cold side of the turbo that is allowing movement.
Good luck!

Mark

Those marks are the lube where the O ring was blown out... but I know something must be moving. I never had this problem before, now 2 O rings in less than 2 weeks...