Sorry if these sound stupid but I did a search and I still have a couple Q's.

1. Will non-mandrel bent piping hurt air flow enough to get any lag in air flow?

2. Should I expect to see a pound of boost loss through the intercooler (heard this is possible).

3. Do I need to upgrade my fuel system if I'm planning on staying around 5-6 psi?

4. Where did you have your BOV port mounted on the custom piping?

5. What kind of connecting materials did you use to hold the piping together? (clamps, hoses, etc.)

6. Where and how did you mount the IC? The pipes don't just hold it up do they?

6. Are there any problems I can expect?

bumpy bumpy

Erik? XtremeRS? Anybody?

>Sorry if these sound stupid but I did a search and I still
>have a couple Q's.
>
>1. Will non-mandrel bent piping hurt air flow enough to get
>any lag in air flow?

Not really. My press bent piping works just fine, althogh mandrel is the best way to go.
>
>2. Should I expect to see a pound of boost loss through the
>intercooler (heard this is possible).

Yes, i saw exactly 1 psi pressure drop from the IC
>
>3. Do I need to upgrade my fuel system if I'm planning on
>staying around 5-6 psi?

Not if its already up to par, and your A/F ratio and EGT's are already good before the IC install.
>
>4. Where did you have your BOV port mounted on the custom
>piping?

Mine is on the IC outlet pipe, much like HRC setup. Its the pipe that goes from the IC outlet to the TB inlet.
>
>5. What kind of connecting materials did you use to hold the
>piping together? (clamps, hoses, etc.)

I used some rubber hose, like radiator hose, cut in sections to make my own couplers. I got the hose from Napa, and its a very strong hose. I got some heavy duty, constant torque hose clamps from Napa also, to hold it all together.
>
>6. Where and how did you mount the IC? The pipes don't just
>hold it up do they?

You can do a search, i have several posts of pics of my setup. I used a hole that was already in the frame, to mount to the one bracket that comes off of the IC. Then fabbed up the rest of the brackets with metal. If you cant find the posts, then i can repost some pics for ya.
>
>6. Are there any problems I can expect?

You just have to use some imagination to get it all together. You will need to cut out the black metal bracket where the stock intake goes through, under the fuse box, to make room for the new piping. Unbolting the fuse box will help to fit and get room for everything while you work.
>
>

Here's some pics of my setup courtesy of Fast420A.

http://www.fast420a.com/images/Kris/intercooler/

Once again you guys were a huge help :thumbsup

Yup, he beat me to posting the link to my own site.




________________________________________________________________________________________
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www.Fast420A.com

I just got mine installed a couple of days ago. Here's some pics.

Front view. I removed the fog light(?) cover(opened up the hole on the left) so I could get as much airflow ducted as possible. That left hole has the radiator right behind it, kind of blocking straight flow. So what I did was I ran the duct really low, into the bumper, so that it would have room to get deflected downward. Oh, all of this ductwork is made from aluminum flashing material and pop-riveted into place onto the bumper and frame.


Bottom duct view. You can see how low I went with the ducting in these pictures. You can see the funnel I made to mount to the IC. It's 3 inches out, and mounts directly to the intercooler. I put a screen on the front just in case a big rock comes hurling through one of the holes. The frame for the funnel was made from a 4 right angle brackets and a couple of small sheets of steel - all pop riveted to the 3 inch flashing. It makes a somewhat rigid box that fits right in front of the IC, is bracketed to the IC, and can be removed with the IC. Like I said, the front ductwork is all pop-riveted to the bumper/frame, so the funnel just slides(kind of) over the front ductwork.



Inlet. I'm using the 90 bend as the inlet.


Outlet. And the 45 as the outlet.


Bottom Bracket. I used 2 of the bracket holes to actually mount the IC. The one here is the first one that I made. First thing I did actually - lined it up so it was nice and straight, facing forward, making sure that the inlet and outlet were accessable. Then I marked the spot for this bracket and used a self-taping sheet metal screw to hold it to the frame.


Top bracket. Then I fashoned another pice of 90 bracket material to hold the top-most IC bracket. First I cut the bracket to size, bent it into shape, marked the location where I wanted it. Then again I just used a self-taping sheet metal screw to hold it to the body.


Discharge. I drilled a bunch of holes in the wheelwell cover so the air could discharge. And that's my boy, who held the light.


So that's that.

Waiting for my 105 amp Mig welder to arrive so I can make the piping - it just shipped today. I already figured out what all pipes/couplers I need and where to get them. I'm going to use all mandrel bent piping. It'll be 2-1/4" from the compressor to inlet. A short mid-pipe from the outlet to the big hole that used to be for the intake. That one'll go from 2-1/4" to 2-1/2. Then the upper pipe will be all 2-1/2".


95 Eclipse RS : 5 speed
Jeep TB writeup - http://www.dimensia.com:81/jimbo/JeepTBfor2gnt.html