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Custom intercooler and piping plus general fab - Hardtuned.net

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Custom intercooler and piping plus general fab 

34 replies to this topic

#1 1zz-fze

  • Joined:07-September 08
  • Location:Australia WA
  • Car:1999 JDM S15

Posted 13 December 2012 - 07:25 PM

Hey guys just thought I would share where I'm at with my car.

I started off doing a simple bolt on turbo swap but when looking at intercooler kits I couldn't decide which one was best for my application. I saw a few of the guys on here make their own "in-bay" intercoolers so I decided to give it a go.

All the work on my car I have done myself at home and most of the fab and welding I do at work as I'm an apprentice pipe fitter/welder.

Will throw some pics up later tonight.

Cheers


#2 1zz-fze

  • Joined:07-September 08
  • Location:Australia WA
  • Car:1999 JDM S15

Posted 13 December 2012 - 11:28 PM

really, i thought it was big compared to some of the ones ive seen in the shops. i used baffles and stainless swarf inside and it doesn't seem that restrictive, but ill look into it a bit more.

thanks

#3 1zz-fze

  • Joined:07-September 08
  • Location:Australia WA
  • Car:1999 JDM S15

Posted 14 December 2012 - 12:04 AM

Ok, thanks for the info. I mainly want to run one because I noticed the intake pipe was a little bit oily inside. The company I work for has a valve shop aswell so they should be able to sus out the flow of the can etc..

Cheers mate

#4 1zz-fze

  • Joined:07-September 08
  • Location:Australia WA
  • Car:1999 JDM S15

Posted 14 December 2012 - 07:36 PM

Figured out the turbo side piping today. just a quick question, what are you guys using on the end of the pipes to stop the silicon joiners coming off? Can you just run a bead around the end?

#5 R32GTRS

  • Joined:24-August 09
  • Location:Australia SA
  • Car:RB25 R32gtst

Posted 14 December 2012 - 08:32 PM

i just add some weld, not always the entire way around, you probably dont need to with custom piping because it should fit perfect, but i do anyway

Edited by R32GTRS, 14 December 2012 - 08:33 PM.


#6 1zz-fze

  • Joined:07-September 08
  • Location:Australia WA
  • Car:1999 JDM S15

Posted 16 December 2012 - 12:02 AM

Ahh yeh I've seen that done before, just don't like the look of it so ill have to hide it some how..

#7 Simon-S14

  • Joined:18-May 04
  • Location:Australia SA

Posted 16 December 2012 - 07:21 AM

well no the pro way is to use wiggins clamps... looks pro and will never blow off ever.

#8 1zz-fze

  • Joined:07-September 08
  • Location:Australia WA
  • Car:1999 JDM S15

Posted 16 December 2012 - 08:56 AM

Yeh they look good, I already have the silicon joiners though.

#9 S15_Steph

  • Joined:06-June 12
  • Location:Australia TAS
  • Car:S15

Posted 17 December 2012 - 04:11 PM

I did the exact same thing a few years ago on my old S15, worked really well, just make sure you shroud the sides, so the air can't bypass the rad. I used 90 degree silicone reducing bends for the pipework into the cooler, made it really easy and direct, and weren't hard to find. All steel pipes were lobsterback :) I don't have any pics tho unfortunately

#10 1zz-fze

  • Joined:07-September 08
  • Location:Australia WA
  • Car:1999 JDM S15

Posted 17 December 2012 - 07:02 PM

Cool, glad to hear it worked well! Ill have to make up some shielding then so the air doesn't escape. shame you don't have any pics, I like looking at different setups for ideas.

#11 S15_Steph

  • Joined:06-June 12
  • Location:Australia TAS
  • Car:S15

Posted 20 December 2012 - 02:19 PM

TBH, yours looks almost identical to what I ended up with ha ha. On the cold side, I found it easiest just to make up the lobster, it was hard to get right otherwise. from memory, I even ovaled the pipe a bit to make it easier to get a tightish turn out of the cooler.

#12 1zz-fze

  • Joined:07-September 08
  • Location:Australia WA
  • Car:1999 JDM S15

Posted 22 December 2012 - 03:47 PM

Cool, glad I'm on the right track. Thanks for your help:)

#13 stevos13

  • Joined:17-May 10
  • Location:Australia QLD
  • Car:s13

Posted 30 December 2012 - 12:46 AM

Nice work mate.
Not to discourage you because I am often wrong, however I'll be interested to know if you have any overheating issues once complete. A lot of people run these intercooler touching radiator setups, obviously successfully. I believe there would be too much heatsoak, although they do make for a neat engine bay. Get her going, give it a good long thrash and maybe you can give us some feedback.

#14 1zz-fze

  • Joined:07-September 08
  • Location:Australia WA
  • Car:1999 JDM S15

Posted 30 December 2012 - 03:43 AM

Thanks mate. I still haven't had a chance to finish it off, was really busy with work leadin up to Xmas.

I'm pretty confident that it will work efficiently, but I guess we will see how it goes. Will keep you updated.

#15 1zz-fze

  • Joined:07-September 08
  • Location:Australia WA
  • Car:1999 JDM S15

Posted 11 January 2013 - 12:01 AM

Posted Image
getting there, slowly..

Posted Image
intake pipe is next.

Edited by 1zz-fze, 11 January 2013 - 12:07 AM.


#16 1zz-fze

  • Joined:07-September 08
  • Location:Australia WA
  • Car:1999 JDM S15

Posted 11 January 2013 - 12:06 AM

sorry about the crappy pics but you get the idea..

quick question, i was going to connect up a mbc to the turbo side pipe but im going to buy an ebc and was just wondering if it connects up the same way?

cheers

#17 R32GTRS

  • Joined:24-August 09
  • Location:Australia SA
  • Car:RB25 R32gtst

Posted 11 January 2013 - 09:20 AM

yea just weld a nipple on

#18 1zz-fze

  • Joined:07-September 08
  • Location:Australia WA
  • Car:1999 JDM S15

Posted 17 March 2013 - 07:07 PM

hey guys, finally got around to finishing the intercooler setup and got the car tuned but still need to make an airbox for the pod filter.

Posted Image

#19 STR8E180

  • Joined:30-April 03
  • Location:Australia NSW
  • Car:GTR R34 V-SPEC

Posted 17 March 2013 - 07:15 PM

looks very nice dude !

#20 silver silvia

  • Joined:22-March 05
  • Location:Australia NSW
  • Car:nissan S15 200SX

Posted 26 March 2013 - 09:38 PM

What radiator shroud is that you are using?
Looks really nice.

#21 1zz-fze

  • Joined:07-September 08
  • Location:Australia WA
  • Car:1999 JDM S15

Posted 26 March 2013 - 11:07 PM

Thanks guys:)

I thought it was an r34 one but someone told me r33? I added an extra piece of plastic to go around the fan because it was sucking air in from the sides.

#22 26_S13

  • Joined:29-September 11
  • Location:Australia QLD
  • Car:s13

Posted 10 April 2013 - 10:42 PM

Havent taken many pics of much work ive done lately.. but got a couple of a 32 gtst with a rb25, I did a turnflow intercooler kit, precision 5858 turbo (3076) on stock manifold with a tial 44mm wastegate off the rear housing. 400rwhp on 17psi pump 98.

Posted Image

Posted Image

Posted Image




#23 1zz-fze

  • Joined:07-September 08
  • Location:Australia WA
  • Car:1999 JDM S15

Posted 14 July 2013 - 03:38 PM

just saw this! nice work mate :thumb:

#24 pig1jz

  • Joined:13-June 08
  • Location:Australia VIC
  • Car:1jz cressida

Posted 19 July 2013 - 05:04 PM

stainless piping then paint it black :wtf1:

#25 26_S13

  • Joined:29-September 11
  • Location:Australia QLD
  • Car:s13

Posted 19 July 2013 - 07:32 PM

Haha yeah I know.. he wanted it stealth though, it was only the intercooler and the pipe work around the cooler painted black, was hidden quite well.

#26 26_S13

  • Joined:29-September 11
  • Location:Australia QLD
  • Car:s13

Posted 19 July 2013 - 07:34 PM

Oops did I crash someones thread? I though it was a general intercooler piping thread. Should read the topic better next time, my bad.

#27 1zz-fze

  • Joined:07-September 08
  • Location:Australia WA
  • Car:1999 JDM S15

Posted 19 July 2013 - 09:01 PM

Hahaha all good man we will make it a custom intercooler pics thread!

#28 FenrirWC

  • Joined:07-December 11
  • Location:Australia TAS
  • Car:s14 Kouki

Posted 30 July 2013 - 05:30 PM

OP that is some nice pipe work you done there starting to make me think about taking up a welding course ha ha ha :D how are your engine temps sitting btw?

#29 1zz-fze

  • Joined:07-September 08
  • Location:Australia WA
  • Car:1999 JDM S15

Posted 31 August 2013 - 10:29 AM

Yeh was I nice little project. Engine temps are pretty solid on the street, I haven't had it on the track yet but I don't see there being any issues. Theres almost no lag due to piping size and length.

#30 Ant Stefano

  • Joined:06-February 12
  • Location:Australia VIC

Posted 30 December 2013 - 09:00 AM

Really love how good that s15 inbay set up looks! I would love to get something made the same!! Any info on your intercooler and radiator sizing dimensions would be really helpful!!! Also info on the shroud how did you add the plastic to it? Did you find the response of the car improved much? Thanks !





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