Intercooler pipes

Beneagles · Mar 16, 2010

From what I have read to date, there seems to be two routes to go when plumbing in 200tdi intercooler as part of coversion project - either spend ridiculous amounts of hard-earned beer vouchers on "specialist" conversion kits, or bodge! So bodge it is - or would be - if I knew the ins and out of turbos, intercoolers, and diesel engines in general - which I don't!
So, my question today is, what temps, pressures or other factors affect the choice of materials etc that can be used to bodge these 2 pipes?
Cheers...

pos · Mar 16, 2010

Beneagles said:
From what I have read to date, there seems to be two routes to go when plumbing in 200tdi intercooler as part of coversion project - either spend ridiculous amounts of hard-earned beer vouchers on "specialist" conversion kits, or bodge! So bodge it is - or would be - if I knew the ins and out of turbos, intercoolers, and diesel engines in general - which I don't!
So, my question today is, what temps, pressures or other factors affect the choice of materials etc that can be used to bodge these 2 pipes?
Cheers...

Temperature isn't an issue really. The bottom hose will be feeding cool air into the intercooler and the top pipe will then be feeding cooler air into the engine under pressure (around 18 PSI I believe?). Ideally you want to be using silicone hose for the bends, and then lengths of steel or aluminium (preferably steel) for the straight bits. There is a site here that sells everything you need. The silicone hose that's thicker (more plys) is better stuff. You'll need at least 3 ply silicone. They also have an ebay store:

Auto Performance Silicone Hoses

Other than that, make sure you have a set of good jubilee clips and make sure each of the joins are tight and well sealed.

-Pos

landowner · Mar 16, 2010

Beneagles said:
From what I have read to date, there seems to be two routes to go when plumbing in 200tdi intercooler as part of coversion project - either spend ridiculous amounts of hard-earned beer vouchers on "specialist" conversion kits, or bodge! So bodge it is - or would be - if I knew the ins and out of turbos, intercoolers, and diesel engines in general - which I don't!
So, my question today is, what temps, pressures or other factors affect the choice of materials etc that can be used to bodge these 2 pipes?
Cheers...

Or..... you could move the radiator back to meet the hoses, after all it's only a couple of brackets to make up. Then you can stick a series grill on it

maybe not

pos · Mar 16, 2010

landowner said:
Or..... you could move the radiator back to meet the hoses, after all it's only a couple of brackets to make up. Then you can stick a series grill on it
maybe not

Yeah and it'd cost more than the bits he needs and end up being more hard work!

landowner · Mar 16, 2010

pos said:
Yeah and it'd cost more than the bits he needs and end up being more hard work!

Yer right, 'cause the steering box is in the way. My mate Tom didn't need to alter any pipes at all because he put the disco boxes in as well which meant that there was loads of room for the disco exhaust..
You dould use flexi pipe for the intercooler and the top hose at a pinch but oil cooler pipes need to be lengthened.
Can you cut and extend the rubber hoses, hydraulic peoples would do it.

pos · Mar 16, 2010

I haven't bothered fitting the oil cooler pipes and I dunno if I should really. Do I need them in the UK, even through a hot Summer?

-Pos

steve bain · Mar 16, 2010

oil cooler pipes? where are they

jamescronin · Mar 16, 2010

Coming off the oil filter assembely on your old td/na and running to the left of the rad as you look at it from the front. It's a pain in the arse if your trying to change your oil on a cold winters afternoon as you can't get the oil hot enough!

Beneagles · Mar 16, 2010

Typical - 5 mins after posting this thread, I got a call out from work...sheesh! Anyway, back now.
Thanks for that Pos. Given that temp is not an issue, has anybody tried using MDPE underground water pipe for the straight sections? Any particular reason why not?
I changed the oil filter adapters over so that the oil cooler pipes from the TD still fit.

Intercooler pipes

Beneagles

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pos

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landowner

Pensioner Pete

pos

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landowner

Pensioner Pete

pos

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steve bain

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jamescronin

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Beneagles

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