I need to know how many of each bend should I buy and what size.
I looked at Stan's pic and could count like (2) 45's, (5) 90's, and maybe (1) 180. If anybody who has a Starion set-up run out and count the number of bends that would be bad ass. I'm also not sure on to go with 2 inch or 2 1/4. Thanks. I'll also make a really good write up and install w/ pics so people like me would quit posting this.

I used 4 180's and two 90's. That is plenty to do the custom pipes. And I am warning you....DONT TRY TO WELD THE ALUMINUM YOUR SELF. It is a bitch. Just ask Hurricane GS. It took 2 days to get my whole set up done.

Don't worry my heli-arc isn't all that great anyway. I'll have my old welding instructor do it for me! Thanks I'll get ordering real soon. Any idea on pipe size?

Just go 2.25 throughout. It'll simplify the proccess. I ordered from JC Whitney (4) U bends and (2) 90 degree angles. I never did the custom work myself, but did sell all the piping to someone who did use them to work.

Hey jason, That someone was me.

I'm posting this to tell you what I used to do with old starion intercoolers. I cut the end tanks off and fabbed it to where both in and out came off one side. The reason being is that the end tanks of a starion cooler are too thin. If you do end up doing this it should cost no more than 200$ thats how much my old shop charged. I made them for g60s and hondas and 2 eclipses. Its real easy just find a fab shop and get an estimate. I'm sure people are going to say this is bad due to flow problems. It will flow the same regardless and it will be less piping to run. late mike

Sort of like this? :



Except with Starion cores instead of two spearco's? That's really not a bad idea..

$200 OUCH!

I had a local shop modify the end tanks of my spearco so the inlet and outlet are on the same side and it costed my $80. the welds are absolutely gorgeous too :)

I'll remember that Dave. I'm terrible with names (equalling screen names) and have sold a lot of stuff over the years.

I'm glad they worked out!

I really like that idea but a little confused. I have never hacked up an IC so please explain HOW to get the tanks on the top and bottom. Also the whole point of me getting the Starion was to kinda cut costs. Right now I think that I'm about 90 bucks away from piping plus modding the IC. (unsure to pay someone or just practice a little heli and do it myself)

The intercooler your talking about is end to end not top to bottom like the pic above. What will need to be done is they will actually fab end tanks on both sides. One side will be just a box, and the other will be 2 chambers with pipes coming out of each. Its not that bad of an intercooler. Its funny because we used to sell spearco cores with welded on tanks for right at 400$ the core only costs 250- 300 depending on the size. Take a look at the stock tanks on the starion, and you will see how thin they are. Believe me bro spend the extra money and make this intercool a design of your own.