I finally got a chunk of time from my cousin to start in on a hard pipe kit for my car. I'll be getting pipe and elbows, and then we will be cutting and welding to make it fit. All this should happen in the next 2~3 weeks.

I have a few questions before I start though.

(1) aluminum vs steel? ~ What is the best material for the job? we can roll the ends so, popping off wouldn't be a problem, but would I be likely to crush the ends? Wall thickness?

(2) what is the best diameter to use? ~ 2", 2 1/4", 2 1/2", which one of these will give me the least amount of headaches for fitment, and the most airflow?

(3) couplers? ~ I was just going to get some silicone with some hose clamps, but Matt is swearing up and down that he has some type of coupler with a "braided" material right inside it that doesn't expand, or balloon out under pressure like silicone couplers will. anyone had problems with that? Also, maybe a different type of clamp?

(4) replace everything, or keep the stock pieces of hard pipe? I'm just wondering on this one. I'm fairly certain it'd be worth it to just replace everything.

(5) Would anyone else be intrested in this? ~ I need to build mine first, and see how it goes, but I can talk Matt into a few more sets. This is for W3SI only!!!! I can't express that enough. I don't want to make these things as a side job, or even a one time group buy on a national website. It brings so many headaches, and my job brings enough. I'm just throwing this out there to cars that are local, so if there is a problem I can get it taken care of. Also, I will have to build one before I know costs. I'm not going to make any money(but don't want it to cost me money to get these out!), though Matt's time isn't cheap.

If there is alot of interest I'll talk to Matt and see what he thinks as far as price.

_________________
Bad decisions make good stories.
Look at it! LOOK AT MY @SS AND TELL ME IT'S PRETTY!

About 4 years ago, I remember reading a thread on one of the DSM board about a guy asking questions about his custom front mount and piping. I can not for the life of me find that thread at the moment...

Here's what I remember:

-You don't need piping larger than your throttle body.
-SS is heavier than aluminum, but it doesn't rust nor crush as easily.
-You'll want a small diameter pipe before the innercooler and a larger after as cooler air is denser.

Given the cfm of the DR500 (Matt M won't give out that info), I highly doubt you'll need anthing as large as 2.5". Most DSM innercooler piping available for 1 14B/16G turbo isn't that large, and I doubt 1 DR500 flows anything close to 438cfm @ 14psi.

Rather that argue flow rates -vs- diameter sizing, let's talk about space. Specifically the driver side innercooler. There's not much room there with the AC dryer in place. You're going to have a tough time working 2" piping in that little space. Not saying it can't be done, but smaller piping will make it easier. Passenger side doesn't look too bad.

Couple more things to think about:
Are you keeping the stock innercoolers?
Are you making a y-pipe to go with these tube?

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06 Blue EVO 9

Dear lord, I don't think I need larger than my throttle body. Was I way off in my diameters?

I'm not really worried about wieght. It's going on a 2 ton car.

How about the same diameter before/after to keep it simple?

Space to work in was what I was thinking, but if I can sneak by with a little larger I'll try it. That's why I was asking about a good diameter to use.

If I am going to make these repeatable for other people I think the best thing to use would be the stock intercoolers. besides, for me, it looks as though replacing intercoolers will be a winter project.

Yes, I believe we will be making a Y-pipe. 'Cause I'm still running the stocker.

_________________
Bad decisions make good stories.
Look at it! LOOK AT MY @SS AND TELL ME IT'S PRETTY!

DNP pipes are 2 1/4" inch I believe (don't remember exactly) and hook up to the stock innercoolers. They fit fine (kinda only go on one way, but it can be done), but with the stock innercooler tubing, it kinda defeats the purpose. They're still your bottle neck.

Speaking of which, if you're available tonight, I'd like to call you and discuss some things. Are you working all weekend?

Working this up coming Saturday so I can catch up to being a week behind. We're stupid busy. My lawn hasn't been cut in going on 2 1/2 weeks now. (which doesn't matter, it's all dead anyway.)

Would say call me tonight, but I lost my phone. It was in my shorts, but I lost those, too... Don't ask.

Stock intercoolers bottlenecking me for now are not that big a deal. they can always be replaced later. As long as everything still hooks up...

Who knows. If we can find decent cores maybe we'll get a Wisconsin intercooler thing going too...

_________________
Bad decisions make good stories.
Look at it! LOOK AT MY @SS AND TELL ME IT'S PRETTY!