ALOT OF INFO!!!!!!!

[onefstsupra89]

for all who doubt me about the PVC pipeing here is a 7MGTE running 443HP and 11 sec on the 1/4 mile using Lowes PVC pipeing......lol
http://www.jblmk3.com/05740b40.jpg
http://www.jblmk3.com/0503a820.jpg
http://www.jblmk3.com/0538a670.jpg

http://www.jblmk3.com/073fdd00.jpg
http://www.jblmk3.com/06cd6f40.jpg
http://www.jblmk3.com/1446ab80.jpg
http://www.jblmk3.com/1739dd30.jpg
http://www.jblmk3.com/164a97b0.jpg

http://www.jblmk3.com/6d2bc0d0.jpg

http://www.jblmk3.com/6ccbc0d0.jpg

I have a new design for intercooler pipes that have really worked well for me. It's very simple and inexpensive and can be done in a couple of hours. If you do these modifications, do them at your own risk and responsibility. I am publishing this site to help people with their Mk3s because it is one of my hobbies and I just want to share what I have learned. All the parts are readily available at Home Depot or Lowes for less than $20.00. You will need a few of the original silicone hoses off your car for the connections to the 3000 pipe and Intercooler. You will also need a piece of exhaust tubing from any parts store and you may want to pick up a couple of new clamps just so it will all be new!

***I have ran a few tests on this system with one stock intercooler and the stock turbo. I used a VDO boost gauge and two SunPro temperature gauges. With my boost controller set to 15 psi at the intake manifold (it has it's own sensor to maintain the proper setting at the manifold) and the VDO tapped in approximately six inches before the intercooler in the PVC pipe, the boost measured 15 psi, just as it should. Then with the VDO tapped in approximately six inches after the intercooler in the PVC, the boost pressure was measured again with the same results, 15 psi indicating no measurable pressure drop from the intercooler.
After this, I took the two temperature gauges and plumbed the sensor probes into the same holes that the pressure measurements were taken in (of course the holes had to be enlarged). With one gauge six inches before and one gauge six inches after the intercooler, the temperature readings were taken at highway runs in fifth gear. It should be noted that these readings were taken in fifth because there was not enough time in other gears to get a reading. On 15 psi runs and 68 degree ambient temperatures, the temperatures before the intercooler reached just under 295 degrees Fahrenheit. This is the section between the turbo and intercooler, and the hottest section in the system (and no, the PVC does not melt or deform)! At the other temperature sensor, after the intercooler, the readings peaked at slightly less than 150 degrees Fahrenheit. That is very good in my opinion, considering the heat that is put out of the stock turbo at 15 psi. I would estimate that the stock turbo is only about 60% efficient at 15 psi and would not recommend running this level of boost with the stock turbo on a regular basis. This test was simply to test the PVC/stock intercooler efficiency. I believe that the stock intercooler system is actually better than most people think. I believe that the pressure drop reported is due to the stock intercooler pipes, not the intercooler it's self These tests (mine) could be a lot more accurately done with better instruments, and are really quite crude, but I have not seen any other efforts to test the stock system. These are just my estimations, and I suggest that you do your own and as I have stated, do these modifications at your own risk! **Any time you tamper with systems on the car that will change the temperatures of the exhaust gases, you are taking risks.** EGTs that are too high will cause severe engine damage. I have not damaged my car with EGTs that have never gone past 1450 F, but that is my car with my tuning. Yours may be different, plus to know for sure, you would need a wide band oxygen sensor, so be careful! By the way, you can get the stuff to make a wide band oxygen sensor yourself or a complete one at http://www.techedge.com.au/vehicle/wbo2/default.htm.
the lower section of the PVC pipes, the turbo to intercooler section which is the hottest, that after about a years worth of use and regular hard driving (I have a VERY heavy foot!) that the PVC has not deformed or melted in any way. If there is a weak spot in the system, I guess that would have to be it, but I have not experienced any damage or downtime at all in the 2.5 years I have been running this setup.

PARTS YOU WILL NEED!!!!

http://www.jblmk3.com/05240110.jpg

5 foot straight section of 2" Schedule 40 PVC Electrical Conduit
B. (3) 2" Schedule 40 Electrical 45 deg. standard radius**
C. (1) 2" Electrical PVC Coupling
D. (1) 2" Schedule 40 PVC 'Y' 1-1/2" into 2"*
E. High heat spray paint
F. 1' section of straight 1" Schedule 40 PVC*
G. (1) 1" Schedule 40 PVC coupling*
H. Short section of 2" inside diameter exhaust tubing or just a 2" ID exhaust tubing coupling
I. Oatly Purple Primer cleaner for CPVC or PVC
J. Oatly All Purpose Cement for PVC, ABS, CPVC
*You only need these parts if you are replacing the 3000 pipe.
**You only need two of these if you are not replacing the 3000 pipe.

K. You will also need these stock rubber pieces to make the connections.
http://www.jblmk3.com/16050f20.jpg

http://www.jblmk3.com/index.htm

CHECK IT OUT IS ALL IN STP BY STEP!!!!!

 

[souprat]

hes been around for a while. everyone knows him and his car. yes its fast. yes pvc can work as ic piping just fine. no pvc does not belong in a engine bay, i dont care if it works or not, plastic just does not belong there. spend the few extera bucks and get mandrel bent exhaust piping and have them welded for you, it will actually look professonal.

 

[Idealsupra]

ugh...this bullshit again...

heres the bottom line...its cheap and will semi work. but its GHETTO.

and the most important factor is it STILL EXPANDS!!!!!!!!!!! the whole reason for using metal piping is the expansion factor...or lack thereof. expansion slows down velocity. and whether you like it or not pvc is still plastic...and it will still expand.

not to mention the thermal properties compared to metal are a joke. and on top of that it STILL has the ability to chip or melt....and have fun with that when it does.

oh and another thing...if you look at what was replaced by pvc... and using all the stock stuff still...theres no damn point really. other then shortening the path of it and getting rid of the restrictive metal elbow on the lower pipe.


this is the bullshit that makes every mk3 owner classified as cheap and ghetto. unfortunetly....in most cases its true. i personally dont have a lot of money but i sure as hell dont cut corners or do stupid shit like this to my car to be "faster" i wait until i can do it right.

 

[starscream5000]

hes been around for a while. everyone knows him and his car. yes its fast. yes pvc can work as ic piping just fine. no pvc does not belong in a engine bay, i dont care if it works or not, plastic just does not belong there. spend the few extera bucks and get mandrel bent exhaust piping and have them welded for you, it will actually look professonal.

:drink1: , It does look pretty decent though. The only things I would be worried about would be a long hard run in 5th gear to redline. I don't think the turbo to IC PVC pipe could last many runs like that at almost 300 degrees. Just to be on the safe side metal tubing would put my mind at ease. The stock hoses would probably flex some too at that much psi, I'd go with silicone hoses.

The rest looks fine . These are just my opinions, but that's how I'd like my setup to be if I was to do something similar.

 

[bountykilla0118]

I agree dont cheap out on stuff like that ..... "the lazy man works the hardest" b/c he is always fixing stuff he should have done right the first time ...... if u want a good deal on IC pipes and anything related check out driftmotions here ya go http://store.driftmotion.com/productdetails.php?sid=145426edd8583e&product_id_int=297

 

[starscream5000]

The rest of the pvc pipe is ok, I'd just be worried about the hot side being subjected to long hard pulls over time.

 

[turbo4toy]

I once made intercooler piping out of toilet paper rolls and the rolls from wrapping paper coated in duct tape.:naughty:

And as Chris Rock said " Just because you CAN do it, doesn't mean its a good idea"

Spend a little more money on eBay or go to a muffler shop and get mandrel bent steal.

 

[mkiiSupraMan18]

I once bought a car from a local metal fabricator/Supra parts specialist...

it had a PVC IC pipe... :nono:

*edit*
I broke it in half...

 

[born2drv]

no one is doubting whether it can work or not.... but for a measly $100 why not by one of those ebay kits with the pre-bent pipes, cut it yourself with a hacksaw, use some duct tape and tape it together how it should fit.... then take the pipes to a welder and have him weld it... shouldn't cost you more then $200 total, maybe $300 with hoses and clamps and everything.... is $300 really worth being such a cheapass over? and like the guys said above, it's not the most efficient setup... $300 could yield you another 20hp or more... so it would be money well spent.

 

[xXxICExXx]

errrr nevermind the durability of it.....what about a bov? :icon_conf I guess it goes on the 3000 pipe, what a silly pain.

 

[Intothenight19]

Yeah it might work but still looks guyblow, and where you going to put the bov? On the 3000? F that...

 

[mkiiSupraMan18]

I did see a set-up using PVC that they got a... I guess I'd call it a Y piece and they adapted it down to whatever size a BOV flange would mount to and did it that way. Sure it was ghetto, but apparently it was working.

 

[boost fiend]

wish i still had my camera.

i have a upper ic pipe thats steel and welded well. i hate it. ive even wraped it in header wrap to keep temps down. now thats hillbilly in my book, but lots of guys think im on the right path(what do they know, they drive pos saturns and malibus!) id rather do it right than use pvc. i might be a hill billy, but id never go that far.

 

[tubbie]

When JBL came up with this cheap PVC pipe it was before the eBay intercooler pipes. Now it wouldn't be worth it to get the PVC when eBay has entire pipe sets for $125 shipped.

 

[Satan]

I agree that the PVC may work in a pinch and that it may be used in a hidden spot (where a stock plastic piece may have been), but it's just not made for this type of application (automotive).

I have used it and relied on it heavily, when trying to mock up the different routing and angles necessary for the different engine swaps and intercoolers. Then I was able to order the right pieces of metal pipe.

I would be more worried about the melting and flamability-type of properties of PVC and what consequences that could have on losing the whole car to some unexpected fire.

 

[shades0fgray]

I could be wrong, but I thought if you heated PVC it released chlorine gas.

Also, doesnt chlorine corrode aluminum? or is it ammonia that corrodes aluminum?

oh well.. just throwing it out there.

 

[mkiiSupraMan18]

^ Interesting info, if true.

*edit*
Mustang guys are doing it... so you know it isn't rice.
http://forums.stangnet.com/archive/index.php/t-465844.html

*edit #2*
It only releases gas when it is burned.

 

[chriso]

When JBL came up with this cheap PVC pipe it was before the eBay intercooler pipes. Now it wouldn't be worth it to get the PVC when eBay has entire pipe sets for $125 shipped.

So true !!!

Tubbie, where do you get all those cool vid clips ???

 

[loki2043]

i dont think pvc has chlorine in it... i work at a pool shop. chlorine usually flows through it though lol. and chlorine will eat almost anything metal.

 

[xXxICExXx]

I believe mods should be 50% performance 50% style. I see the performance part of it, but its missing the style. Ya know, it probably does work just as well.......but i would LOVE to see that car years down the road. Doesnt matter if it works now, welded metal lasts longer than glued plastic, especially under pressure.