Hard pipe kit - DIY guide

[swinks]

Well, seeing people on forum still interested in hard pipes I decided to put here bit of guidance how to built your own hard pipe kit.

What's needed?
1. some skills in cutting aluminium pipes
2. aluminium pipes (i.e. off eBay)
3. silicone couplers
4. two 6mm (1/4 bsp) brass hose fittings
5. metal weld adhesive
6. mikalor style clamps

Actually there 3 sections of rubber hoses which we want to replace by aluminium ones.

1. Section off rear turbo.
Requires:
1x 51mm (2") aluminium elbow (150mm leg), I've found one on eBay for 13.65 GBP, here:
http://cgi.ebay.co.uk/51mm-2-Alumini...item4cefd3e443
2x 51mm (2") silicone couplers straight, 3.50 GBP each
here: http://cgi.ebay.co.uk/BLUE-Silicone-...item20b1c9bddb
4x mikalor style clamps size 54 to 64mm
Aluminium elbow needs to be cut to size both legs.

2. Section from y-pipe to intercooler (next to coolant expansion tank)
That's a tricky bit, because there's wired angle and it's very hard to find right size aluminium bit of pipe. After several attempts and trys I've found on US eBay aluminium elbow 70 degree bend.
That's fits perfectly, but it's only available in 70mm ID, not 63mm. Doesn't actually matter. Otherwise you have to buy 45 degree elbow of 63mm ID pipe and using mandrel bend one to 65 degree (custom exhaust shops/garages?). Well back to the point.
We need:
1x 70 degree aluminium elbow, which I found only 70mm ID from that site (29 GBP):
http://cgi.ebay.com/ebaymotors/ws/eB...K%3AMEWAX%3AIT
1x 70mm to 63mm silicone elbow reducer 45 degree (12.30 GBP), here:
http://cgi.ebay.co.uk/Silicon-Hose-4...item1e58d276ae
1x 70mm to 63mm silicone straight reducer (5.30 GBP), here:
http://cgi.ebay.co.uk/Silicone-Hose-...item2c55f4eece
2x mikalor style clamps size 67 to 75mm
2x mikalor style clamps size 73 to 81mm
Obviously aluminium and silicone elbows need to be cut to size. And job is done.

3. Section from intercooler pipe to throttle body (including plastic elbow).
Another tricky bit. It's because same story with getting right angle due to airbox, but also because we are replacing plastic elbow with two vacuum outlets. So, we need:
1x 70mm aluminium elbow 70 degree (same story as in above), which I've found for 29 GBP here:
http://cgi.ebay.com/ebaymotors/ws/eB...K%3AMEWAX%3AIT
1x 70mm to 63mm silicone straight reducer (5.30 GBP), here:
http://cgi.ebay.co.uk/Silicone-Hose-...item2c55f4eece
1x 70mm silicone elbow 135 degree (15.40 GBP), here:
http://cgi.ebay.co.uk/70mm-2-75-Sili...item4aa2321362
3x mikalor style clamps size 73 to 81mm
1x mikalor style clamp size 67 to 75mm
Silicone 135 degree elbow needs little cut to size, also one leg of aluminium elbow needs to be trimmed down.
Now, important part - making vacuum outlets. We need:
2x brass hose fittings 6mm (1/4 bsp), like that one (2 GBP each):
http://cgi.ebay.co.uk/1-8-bsp-6mm-Br...item4cf030af8e
1x "metal weld" adhesive, it can't be any epoxy-like adhesive, must be one which creates strong bond to metal. I've found this one superb (4.75 GBP)
http://cgi.ebay.co.uk/Quick-Steel-Me...item19b33f5863
So, after all measures of aluminium elbow and cut to size:
- drill two holes same size as thread size on brass hose fittings. IIRC it was 10mm. Remember to mark where you need these holes. Get proper alignment.
- cut thread off fittings leaving just 2mm of threads.
- using recommended "metal weld" adhesive, glue both hose fittings, and wait 24 hrs to get full bond strength.
Well, that's how to make one piece of aluminium section from TB to IC.

My recommended site to get not expensive clamps is here:
http://cgi.ebay.co.uk/1-x-ANYSIZE-IN...item20b228a375

That's it. Cost of total material (pipes, silicones, clamps) is approx. 143 GBP. IMO quite bargain.

If admin feels that this guideline is anyhow helpful, feel free to move that thread to Club resources.

Here time for pictures and description (some of pictures just for illustration purposes):
1. "metal weld" adhesive
2. prepared pipe for vacumm outlets (overall view)
3. prepared pipe for vacumm outlets (inside view)
4. pipe with done vacuums
5. hard pipe next to coolant expansion tank fitted
6. hard pipe next to airbox fitted
7. vacuum fittings as should be

[Gly]

great work!!

very impressed with the DIY work and artical

you've made things much easier and cheaper? to get your own hardpipes kit!
and it clears the stock airbox!!

have some rep!

[Barney]

Tomasz,

Looks good.
Excellent write up

[Wodjno]

Excellent article and write up Tomasz

[lancerevo3]

well done very helpful.

[swinks]

Here's engine bay look:

[andyleaves]

Just seen this well done mate... REP

[SteveH]

Awesome write up mate. How come you changed from your old DIY setup?

[swinks]

Simply, wasn't happy with few bits, and most of all returned to stock panel filter. Previous setup unfortunately didn't clear stock airbox.

[hbkuk1]

Can't believe I've never seen this thread! This will be my next task

[swinks]

Well, recently I'd do some minor cosmetic changes to write-up above...
1. Brass hose take-offs, more popular are 1/8NPT. Make sure all brass fittings are threaded into pipe (as seen on one picture) and then sealed with liquid weld.
2. Instead of fiddling with aluminium pipe and mounting there take-offs, there is another route with take-offs designed to use with silicone pipe. Simpler. They can be fitted in elbow prior to throttle body.

[Br1jzl]

Does anyone know where to get the 70 degree pipes from, the eBay store has changed to 75 degrees

[Bender]

Does anyone know where to get the 70 degree pipes from, the eBay store has changed to 75 degrees

Just use 45 degree pipes if you can't get a hold of 70 degree pipes, Me and few other's have used 45 degree pipes.

[swinks]

Does anyone know where to get the 70 degree pipes from, the eBay store has changed to 75 degrees

Elbows 75 degrees are ok. Better than 45's

[piggies]

Elbows 75 degrees are ok. Better than 45's

Any chance you could pm me. ☺

[Br1jzl]

Found all the pipes from a website, including the 70 degree bend, silicone hoses, clamps and nipples from www.bestpowerracing.com, just dropped them email and think it was around the same price. Only needed to get the jb weld