Intercooler Issue

[Z82]

Please bear with me as I don't know much about turbo cars, this is my first petrol turbo that I have owned.

I have a B2 90 quattro that has had a 3B fitted it has a custom FMIC and a chipped Motronic ECU running 265bhp as far as I'm aware.

I've only owned the car 2 months, previous owner bought the ECU from someone off this site a long time ago and only fitted it a couple weeks before I bought the car.

Car seems to run great but when I give it some beans the intercooler pipe keeps blowing off, I have changed the band clip for a heavy duty stainless steel double bolt type and it still blows off.

Any ideas what my issue might be?

[tekstil]

Are the pipe ends flared?

[De80q]

As tekstil said, is the piping flared? I had the same problem with my 10vt swap when I first did it. I don't have a bead roller, so I made up a crimp tool that basically did the same thing. This gives the couplers something to grab onto if they try to move.

[Z82]

Are the pipe ends flared?

Its silicone onto aluminium and I dont think it is flared, should it be?

[LHD_Kid]

Use JCS Hi Grip stainless clips, not the mikalor type you talk about. They spread the clamping pressure too much.
Wipe the inside of the hose and the outside of the IC with brake cleaner, then use hairspray as lubricant to push the hose on.

Tighten it, the spray will act as a type of glue. You'll be fine

[tekstil]

Its silicone onto aluminium and I dont think it is flared, should it be?

Aluminium pipe end needs to be flared, otherwise your silicone hose will slip off under boost no matter what type of clamp in use.

[LHD_Kid]

Easiest way is to tig weld 3 small blobs instead of a full flare.

I still think a decent quality thin clamp and hair spray will hold it. Held my non flared IC hose in place for almost 10 years.

[Z82]

This is the clamp I'm using, scared to over tighten it encase I distort the pipe being aluminium.
What does the hairspray do?
clamp.jpg

[LHD_Kid]

Yes... And these are the clamps you shouldn't be using...

JCS HI-GRIP... simples...

[LHD_Kid]

use hairspray as lubricant to push the hose on.

Tighten it, the spray will act as a type of glue. You'll be fine

[LHD_Kid]

Car seems to run great but when I give it some beans the intercooler pipe keeps blowing off, I have changed the band clip for a heavy duty stainless steel double bolt type and it still blows off.

Did you sort this out?