what charge pipe are people using..

[DaleGT]

nice one mate is yours a custom one?? how much is it all costing bud??

 

[Reuvers]

I am sure there smaller because you have to change the silicone pipe that connects the charge pipe to the turbo when you do the ko3s conversion.

i have no idea what you're talking about. WHen I changed my k03 to k03s I still used the oem black pipe on the chargepipe to connect to the turbo.

Maybe, just maybe, the unsilenced K03s has a smaller pipe, but like said mine was exactly the same (i have a silenced k03s)


Dale, I just welded my custom route yesterday. really happy with it. Now need some time to fit the new cooler and pics will be up!

costs would be 3 90 degree bends like I mentioned on the first page + 2 aluminum nipples (has to be aluminum or else you can't weld it to the aluminum bends). the nipples have to be 8mm and 25mm.
Then add welding costs and charge pipe is done.

to add: and quite a bit of time to cut everything to the perfect size.

and a golf 2 reservoir

 

[cuprachrissy]

like I said on the previous page, all you need is 3 90 degree bends in either 60mm or 63mm. whatever you want.
On the third 90 degree bend, which goes down in the wing by the headlight, next to your horn, you have to stick a 45 degree bend on. then another 45 degree that which brings you to the intercooler.

Danny used 2 90 degree bends from turbo, and then a 45 degree one, because he doesn't have a washer bottle fitted there anymore. If you opt for the Golf 2 reservoir you'll need to fit a 90 degree one.

As danny knows, a little bit of searching where the best place to buy pipes/hoses from. Remember, cheapest doesn't always mean great quality. Especially as you'll be running fair amounts of boost.

Don;t think I can make it any clearer than this

i understand this mate but you are saying as if everyone is good at welding and can fork out to get it weleded together. and all im going to do is buy a lenght of 2.5" of aluminium tubing, then get someone (somehow) to weld the 2 nipples on the pipe that comes from the turbo (8mm and 25mm nipples). i'm guessing all you need is 1 90degree reducer coming of turbo (63mm-?) and then another 90 degree 63mm elbow to run down by the side of your engine. then place a third 90degree elbow on the end of the pipe and bring it into the wing where the horn is. (smaller washer bottle from a mk2 or mk4 golf needed) then to bring the pipe along to the intercooler you need 2 45 degree elbows a bit of pipe in between and a reducer onto your intercooler job done. do you need your ac removed for this as it seems a very tight fit looking at it today.? just want this cleared up once and for all.
(p.s i know i have to cut the long bit of pipe im buying to size!!)and i have read nearly every thread on this took be bl**dy ages

 

[Reuvers]

ok chrissy I'll make this as easy as possible for you:

buy 3 aluminum 90 degree bends in either 60mm or 64mm (up to you)

for sake of this example, lets say you chose 60mm

get one of the bends and place it on the turbo using a straight reducer 60mm to 51mm. It will be too high above the block, so you cut it down so it runs just above the rear of the block (refer to the picture Dale GT posted).

In that same bend you need to cut 2 holes, 1 8mm one 25mm. Its up to yo where you place these. you end up with somethign like this:

then get the second bend. Place that on the other side thats not mounted on turbo and measure until it runs just past the left side of the block (again refer to picture Dale posted).

Then get the third 90 degree bend and measure that so that it goes down the wing infront of the Golf 2 reservoir, so it sits above the hole where the horn is situated.

Now this is all things you can do yourself as you only need a pencil (mark where to cut), a saw to cut to size, and a drill to drill the 8mm and 25mm holes.

Then find a welder close to you, on the web or something, who can aluminum weld in the evening hours. THis should take him about half an hour/45 minutes.

you end up with this (mine i finished yesterday)

If you do it this way you will see no silicone in the bay which imo looks best

 

[Reuvers]

to add crissy, the way you're explaining it is using silicone.
reason I wouldn;t do this is because silicone is just as expensive as the aluminum bends. So you might as well get a welder to put the pipes together for about 30 quid.

 

[karls cupra]

thats very good work mate where did you get the nipples from...

 

[cuprachrissy]

to add crissy, the way you're explaining it is using silicone.
reason I wouldn;t do this is because silicone is just as expensive as the aluminum bends. So you might as well get a welder to put the pipes together for about 30 quid.

nice work, this part of the pipe (pictured goes straight to the ic or you have to add 45 bend? thanks

 

[Reuvers]

thats very good work mate where did you get the nipples from...

thank you

I actually made the nipples from solid aluminum pipe, and drilled/milled to the right size.

but look up 'hose connectors' on ebay. they have to be aluminum though because metal won;t stick when welding!

 

[Reuvers]

nice work, this part of the pipe (pictured goes straight to the ic or you have to add 45 bend?

also behind the bumper its up to you to go with silicone or aluminum pipe. I chose pipe, as the air flows slightly better in them.

So in the picture I stuck a straight 60-60mm connector on the circle. A 45 degree on that, another silicone connector to a 90 degree bend. then depending the length of that, a straight pipe in 60mm.

Then put a 45 degree silicone bend on that reducing to your intercooler port size (mine was 57mm)

 

[karls cupra]

whats the wall thick ness of your pipes is it 1.5mm i can get 90deg pipe called welding bends for exhaust 60mm dia but there alluminuised not alloy not sure if these are ok but they say welding bends..

 

[Reuvers]

sorry carl not sure on thickness of the pipes. But 1.5 sounds right.

as for the difference between aluminised and alloy i also don;t know. thats where my english stops lol

Just type 60mm pipe on ebay, or forge site, etc. those are fine

 

[cuprachrissy]

right just got offf the phone to a friend(of a friend) who works at rsr (company that fits custom exhaust, tyres and alloys. reuvers, dint know if u knew them as you are from holland)anyway... he said he cant bend me all the pipework i needed in 2.5" (63-64mm), may need one or two hose connectors. the only thing is he can only do it in stainless steel. im sure i've read on here or edition38 that s/s gets hot really easy and aluminium is better for ic's. do you think this will be ok to do as he will be doing it for me at mates rates .

 

[Reuvers]

imo: simple answer...no.

Why do you want to bend the alloy yourself? Why not get the 3 90 degree bends I said 4 times now?
if a bend costs about 15 quid then thats 45 quid and you've finished the entire part which is visible in the bay.

 

[cuprachrissy]

imo: simple answer...no.

Why do you want to bend the alloy yourself? Why not get the 3 90 degree bends I said 4 times now?
if a bend costs about 15 quid then thats 45 quid and you've finished the entire part which is visible in the bay.

ive been looking on uk ebay and the only 90degree bends they have are only about 150mm, 6 inches long. surely that isnt long enough? these are what ive found.
http://shop.ebay.co.uk/items/_W0QQ_...286.m270.l1313&_odkw=60mm+90+degree&_osacat=0

 

[karls cupra]

ive been looking on uk ebay and the only 90degree bends they have are only about 150mm, 6 inches long. surely that isnt long enough? these are what ive found.
http://shop.ebay.co.uk/items/_W0QQ_...286.m270.l1313&_odkw=60mm+90+degree&_osacat=0

yeah i see them mate need to be a good few inches longer than that dont they mate
got a felling that this might be a nightmear to get done but we will see ...

 

[cuprachrissy]

yeah i see them mate need to be a good few inches longer than that dont they mate
got a felling that this might be a nightmear to get done but we will see ...

lol me too mate, dont get me wrong reuvers has been awesome in the way he has shown us how to do it and what is needed but i am struggling to source the pipes needed, he lives in holland so might source these parts easier. might have to get a 2m length of 2.5" ally tube (50quid) and just purchase elbows etc from forge or someone.

 

[Reuvers]

before you guys get elbows, why not buy these bends first? You'll see that they are long enough.

Think about it:

leg length is 150mm, then comes the actual bend which is another 60mm. Then you stick the next bend on it with another leg length of 150mm and other 60mm of the bend thickness again.

That's 420mm which is plenty!

Its too much tbh

 

[cuprachrissy]

That's 420mm which is plenty!

420mm (16.5 inches) is plenty to do the engine bay run?sorry i must be absolutely thick but you are saying that this will do?

 

[cuprachrissy]

just found this that seems a bit longer and cheaper
http://cgi.ebay.co.uk/2-5-64mm-ALU-...286.c0.m14&_trkparms=66:2|65:15|39:1|240:1318

 

[Reuvers]

MATE! its 3 separate 90 degree bends that you weld onto each other!!

the 420mm I said is only from the turbo till around the first corner of the block. then another bend on that will bring you to the wing