While my GF was out getting her hair done, I decided to make my own cold side intercooler tube.
I picked up some 3" inch 76mm 135 Degree Elbows from Aliexpress and one piece of straight tube a while back and I have some 1/2" plate laying around, so I thought I had enough materials laying around.
I pulled the stock plastic tube and throttle valve off, then traced the valve and transfer punched the holes on the plate. Then cut and ground it into a rough shape. The center hole is about 2 3/8" in diameter, so I drilled it out with a hole saw.
I diced up the tube into roughly the correct spots plus some extra, then I used my eyecrometer to measure out the correct angels. Because I was going from 3" tube that had an I.D. of 2 7/8"(2.625" at the bend) to a 2 3/8" hole, I had to slice the end of the tube up a little. So I mathed out the circumference @ 8.247" - 7.461" = 0.786" Ă· 0.060"(cut-off wheel kerf) = 13.1. So I put 14 cuts in the end of the tube and used one of the clamps to squish it together over the hole saw. After welding, I popped the hole saw out of the end, cleaned it up a little and dialed in the angels a little better. I welded it to the plate, sanded the inside a little and welded the next piece on. That's when I realized that I had an issue with dropping down to the stock hose on the intercooler side. I needed a 60mm piece to fit inside because If I made the 3" tube to fit, it would never seal. So put the truck back together and ordered a piece of 60mm from Ebay which should be here next week. And I need to order some shorter hardware. Does anyone know what size bolts they are?
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I picked up some 3" inch 76mm 135 Degree Elbows from Aliexpress and one piece of straight tube a while back and I have some 1/2" plate laying around, so I thought I had enough materials laying around.
I pulled the stock plastic tube and throttle valve off, then traced the valve and transfer punched the holes on the plate. Then cut and ground it into a rough shape. The center hole is about 2 3/8" in diameter, so I drilled it out with a hole saw.
I diced up the tube into roughly the correct spots plus some extra, then I used my eyecrometer to measure out the correct angels. Because I was going from 3" tube that had an I.D. of 2 7/8"(2.625" at the bend) to a 2 3/8" hole, I had to slice the end of the tube up a little. So I mathed out the circumference @ 8.247" - 7.461" = 0.786" Ă· 0.060"(cut-off wheel kerf) = 13.1. So I put 14 cuts in the end of the tube and used one of the clamps to squish it together over the hole saw. After welding, I popped the hole saw out of the end, cleaned it up a little and dialed in the angels a little better. I welded it to the plate, sanded the inside a little and welded the next piece on. That's when I realized that I had an issue with dropping down to the stock hose on the intercooler side. I needed a 60mm piece to fit inside because If I made the 3" tube to fit, it would never seal. So put the truck back together and ordered a piece of 60mm from Ebay which should be here next week. And I need to order some shorter hardware. Does anyone know what size bolts they are?
