intercool system ?'s
 

After checking online, I just can't afford to buy a premade intercooler system. I just enrolled in college and its just a HUGE monthly bill. I now have set out to try and build up my own kit. I decided on the $100 ebay intercooler, I THINK it was 19xsomethingx2?

I need info from anyone who has put one together. How many bends? What bends? How many couplers? yada yada.

Also, I already welded my turbo XS bov's bung into my crossover(the steel one.) I don't think I can re use it. Is there a way to buy just that part? And if the intercooler pipes are aluminum or stainless, what am I gonna do?

I really wanted stripes kit, but I just can't afford it. If someone has already asked this question, I couldn't find the post. So sorry. And thanks for anyone who can help!

john (stripes) mx5projects.com link at the top of the page has a fairly cost effective and excellent setup he sells. may still seem like a lot but things will really add up when you're doing your own setup.

Unless you go semi-ghetto and use radiator hose, exhaust pipe, and worm clamps, you'll be hard pressed to beat his price.

Well, as I stated, I would love to have his kit but I just can't afford it. My college is $500 a month. I can only work part time now also, so my total income is LOW.

I can have pipes bent for free, and welded for free. For clamps I use these bands that are made to hold wheel sensors in. Hard to explain them, but they work alot like a T clamp. I just double them up, thread lock em and use a socket to tighten them.

I do however need to buy pipes and couplers. I don't know how many of what degree's to get. I'd like to go around the radiator. I've searched, but I couldn't find a list of them anywhere.

I'm assuming from memory the turbo outlet is 2" and the throttle body is 2.5". Is it best to expand right out of the turbo or right before the throttle body?

Thanks for the help. I'd love to support stripes, but I just can't.

Go to exhaust shops and grab the scrap pipes from their trash pile. Then find some diesel shops and look for old radiator hoses. Since the pipes will be steel, you can weld in your old bov and limit the need for clamps and silicon connectors. I only use four in my setup- turbo, IC hotside, IC cold side and TB.

Less couplers looks so much better:)

thats exactly what I want to do...4 couplers just like that, does that work out well for ya, seems like it would lessen the issues with leaks etc.

Hey M2cupcar, how many bends and what not did you use in your setup? Would you recommend getting the 2"->2.5" adapter right off the turbo and run all 2.5" pipes? From what I've been told its the cheapest and easiest thing to do.

here I think you'll like reading through this:

https://www.miataturbo.net/forums/sh...iy+intercooler

I have 2" hotside and 2.5" coldside, it works. Whatever's easiest and cheap for you will work just as good. No crush bends though.....or duct tape....or pvc.....etc.

If you've got something to cut the tubing, a grinder and welder - just have at it. Go with 2" - that's all you need and it's more readily available as salvage and easier to maneuver from point to point. I ran my turbo-to-IC pipe through the fender, so it's probably composed of maybe 6 piecs, but only 18" long. The IC-to-TB pipe runs from the mouth by the narrowed rad. It's only three pieces and about 24" long. But I say come up with your own solution based on what pieces you find and your intercooler shape/bungs.

Braineack to the rescue! Thanks, I remember looking at that before. I must just overlook these posts when I search, I read them when they get posted but when I search I don't see em. Thanks!

I read someone talking about the inside of the pipes rusting. Is that a realistic problem? I will paint the outside to protect them.

Does anyone know about a sorce for a new Turbo XS steel bung? I welded the old one in deep, so if I cut it there wont be enough to reweld. Thanks for the help, I always seem to need it.

dont worry about rust...it anit going to happen (especially on alum.). and with the amount of oil my intake sees.......

go to ACE hardware or Sears or lowes. By a 3/4", 1", or whatever size threaded pipe. drill the proper hole and screw it in. Then bust out the JB Weld....Welcome to the world of Jim B's genious.

cut the bov flange off in the pipe area, then weld the old pipe edges to the new pipe. it's ok to be ghetto - really. :)