Intercooler Plumbing

[Eatoniashoprat]

Can anyone give me some advice on building intercooler plumbing?

I'm using the stock wrx intercooler mounted horizontally over the engine. The problem is the intercooler has two intake holes. Since I don't have a spool gun for my mig to weld aluminum I was just going to make the flanges and the pipe out of steel/thin exhaust tubing. It basically just needs to come out of the turbo, make a 90, make a y, then into the intercooler. Is using steel a really bad idea (rust/heat transfer?)? I can't use the original aluminum subaru flanges since they are pointing the wrong direction. I also can't find any aluminum y-pipes. If I could find one of those I could just make the flanges with short pipes sticking out of the intercooler and connect the rest with silicone tubing. Any thoughts/pointers? I'm not too sure what to do here.
THanks,
Mike

[Eatoniashoprat]

Sorry, Its an EJ20 with the turbo in the stock location

[GS guy]

I don't think steel would pose any significant problems, it's been used for ages on air cooled VW turbo engines. Ideally you'd try to work with the original cast pieces and Y section, but not having done this I have no idea if there is any flexibility in re-postitioning the outlet direction. It's too bad really, I think the WRX models have a nice intercooler but too difficult to adapt it to non-OEM applications.

No reason you can't substitute steel connection pieces and flanges though, just make sure the flanges are flat! If you notice excess heat transfer you can always wrap the tubes with insulation. You can also have them ceramic coated for looks, less heat transfer and corrosion prevention. Go for it!
Jeff

[Turbo Haraune2]

there is a special y pipe made of silicone for the ej20. its a performance mod they usually do when increasing pressure.
Im sure this can be modified for your use.
Dont know who maks it...

Why dont you go for a universal E-bay cooler? get them for under 100$ with piping included!
Easyer to mount in a custom setup

[Eatoniashoprat]

Originally Posted by Turbo Haraune2

there is a special y pipe made of silicone for the ej20. its a performance mod they usually do when increasing pressure.
Im sure this can be modified for your use.
Dont know who maks it...

Why dont you go for a universal E-bay cooler? get them for under 100$ with piping included!
Easyer to mount in a custom setup

I thought about this but I was given this intercooler and and have the resources to build the piping so I thought I'd give it a shot. Plus it fits beautifully under the decklid
Mike