Grassroots intercooler piping?

It's looking like there's going to be room in the Rampage's budget (assuming the engine doesn't have any massive issues I've not found yet...) to add an intercooler to its normally non-intercooled turbo engine. I hopefully have a line on a very budget-friendly intercooler- but still have to be able to hook it up... and the intercooler piping sets I've seen are both not nearly as budget friendly and worry me that they won't have the right piping to hook it up right.

Does anyone have any tips on Grassroots ways to build/source the piping and connections? I considered (briefly) PVC, but realized from my experience building a few thing with it that it would not like being hooked up to the hot end of the turbo (might handle the run from the intercooler to the manifold though).

Thanks!

I have an intercooler and piping and silicone connectors from a 240sx with sr20 swap (pretty sure its a cheap ebay kit) that I got at the challenge swap meet last year for $20.

I'll sell it to you for $20?

"I've read" here on GRM of people using 18 wheeler radiator hoses from the auto parts stores.  I was thinking of trying that for the Europa intercooler, which, BTW, is a SR20 side mount.

In reply to Robbie :

That sounds like a good deal to me! I'll PM you about it- thanks! 

Yep, Napa Truck Stores or ones that have machine shops built in to them usually carry the radiator hoses for tractor trailers. These work great for couplers or short straight pieces but you can't really bend them at all.

PVC is just going to frustrate you. Cracking, blowing couplers off since there's no bead.... plumbing rubber couplers will also expand and pop.

I'd rather have low boost and no intercooler than an intercooler comprised of ghetto connections that are always blowing.

Swing by your favorite local exhaust shop and get a take-off truck exhaust, use that for enough straights and bends, just clean it out good first.

For couplers, radiator hose, or cheap silicones are cheap enough, hose clamps can come from junkyards, you can also get rubber intake sections and cut them up to make couplers, GM stuff from 3800s as I recall have some friendly sections.  Lots of options with some junkyarding and creativity.

I have used exhaust pipe and tractor coolant hose as unions, don't use all hose as you will have a LOT of boost lag.  Don't forget to put some kind of raised lip on the steel pipe or it will blow off under pressure.

Paul B

Robbie said:

I have an intercooler and piping and silicone connectors from a 240sx with sr20 swap (pretty sure its a cheap ebay kit) that I got at the challenge swap meet last year for $20.

I'll sell it to you for $20?

We're interested if not claimed.

I'm late to this, but I have a buddy that used a tubular bed frame he got from a craigslist "free" listing for intercooler piping.  Lots of piping, several bends, ultra cheap.

I've used 2 inch car exhaust with good results. Napa hose couplers and the heavier plumbing couplers all with no issues. The trick with the plumbing couplers is go with 2 inch and heat and stretch to the larger 2½ inchish throttle body or whatever.

Besides the bead or rolled lip you can also tack a bracket on each tube and run a turnbuckle or a long bolt to keep each end snug together

If you actually use enough boost to blow those couplers 

On my first ever Challenge car (a turbo Dodge Aries in '09) I used all sorts of stuff including exhaust piping and factory boost piping from other cars.  Really anything that can handle the pressure is fine, it's getting your connections to stay on and not leak that is harder. You do need to know the sizes of the barbs you're hooking to. So, what's the intercooler?

Also, i have one of those 'universal' flexible corrugated radiator hoses making the top run of my charge piping on my turbo Spirit. It was i think $23 Amazon Prime after i looked in the Goodyear catalog for the right length/diameter specs. 

I came to suggest the Napa coolant hose too.... only to see I wasn't the first to the party.

After reading this I wonder if Napa sells more tractor coolant hose to forum members ghetto-charging their junk than they sell to actual tractor owners?

I used scrapp 2” galvanized electrical conduit. Welded on ridges to hold the couplings.  (Radiator hose) 

I can see where exhaust tubing would work well. What about the flexible stuff?

the old turbo dodge mopar trick hacks (back in the 90s and 2ks) was bits of exhaust and radiator hose... can add a bead to the ends of the exhaust bits to keep things from popping off too easily...

Anyone know what the burst strength of Pringles cans works out to? 

I wonder how you'd score in concourse if your charge piping was made to look like Pringles cans. I could see that going either way.