Aluminum IC piping Question

[adoboboy]

OK...I'm 99% done piecing together my turbo kit for my KA. (trying to keep a budget of $1500)
I picked up 6ft of 2.5"dia aluminum piping and 5ft of 3"aluminum piping for only 10 dollars shipped. Is that enough?
I did some research, seems like aluminum is hard to weld and bending it with tight radiuses will cause stress and crimps on opposite ends. Is there a trick anyone can share with me so I can complete my IC piping?
I have access to machines shops at work but i'm not too familiar with terms so please explain in detail.

Constraints: I also want to use the minimal amount of couplings since they seem to be a source of leaks and problems down the road. I also want to snake the piping myself. I like to be thorough with my work and not cut corners. So taking the piping to someone is my last option.

Thanks all ahead of time.

[drftwerks]

is a ll the piping straigt?

[adoboboy]

Yup, they are all straight right now. Their in my office collecting dust.

[drftwerks]

then you would have to have each bend welded from little cuts, or you should go buy some u bends

[ask52]

We built my fmic pipes from 2.25" aluminum but i can't remember how much we used overall? If I can figure out how to post pics I will throw a few up!

Later days.....Josh.B

[ask52]

a few pics

http://photobucket.com/albums/b17/ask52/?action=view&current=P1010015.jpg

http://photobucket.com/albums/b17/ask52/?action=view&current=P1010016.jpg

http://photobucket.com/albums/b17/ask52/?action=view&current=P1010017.jpg

[SochBAT]

Sooo awesome. I saw a guy jsut having them expanded into each other, and using like, weatherproofing glue or whatever it was. Looks okay.

[theicecreamdan]

lovin that crazy miter cut intercooler piping

[adoboboy]

a few pics

http://photobucket.com/albums/b17/ask52/?action=view&current=P1010015.jpg

http://photobucket.com/albums/b17/ask52/?action=view&current=P1010016.jpg

http://photobucket.com/albums/b17/ask52/?action=view&current=P1010017.jpg

Thanks for the pictures!.
That is how I pictured it. So you just Tig welded them together?

Woo hoo.. my 200th Post!

[ask52]

Yep just lay it out nicely and tig it up :) Oh and post some pics of the finished product :bigok:

[sr240mike]

You could always BUY the bends or since you have a machine shop, you may have a mandrel bender. Bead rolling the ends or welding around the pipe is necessary to keep the couplings on. Use good quality silicone couplers (use hairspray on them) and use T-bolt clamps. Good luck, its a lot of work.

[adoboboy]

You could always BUY the bends or since you have a machine shop, you may have a mandrel bender. Bead rolling the ends or welding around the pipe is necessary to keep the couplings on. Use good quality silicone couplers (use hairspray on them) and use T-bolt clamps. Good luck, its a lot of work.
Hmm hair spray, not a bad idea. I wouldn't have thought of that. Thanks

Yep just lay it out nicely and tig it up Oh and post some pics of the finished product .
Yeah Of course I will...im a picture whore.
Btw the look with the welds look badass...

So how many couplings do you guys use? 6? 8?
the only site I have for hoses that seems reliable is www.hosetechniques.com do you guys know of others?

[ask52]

Btw the look with the welds look badass...
Thanks man! I like it also, plus its a bit different then the regular bolt on kits


So how many couplings do you guys use? 6? 8?

We bought all are couplers from a local heavy-duty truck shop. They have bulk lengths that can be cut to your desire. We also bought a cool 2.25"-3" with a 90 elbow. Worked perfect for joining up to the tb. All of the pipe ends have a thin slice of a larger diameter pipe welded on to keep the couplers from blowing apart. As of yet, Besides the 1 time I forgot to re clamp 1 of the couplers I have NEVER blew an ic pipe. That's running daily of 11psi and 15psi on the track.

So far so good.

Josh.B

[NemeGuero]

mandrel bend the piping and keep it as few pieces as possible!! how many bends you make depends on where you want to route the IC piping through your body