That Age old problem

[APNess]

Boost leak...

This applies more to the guys with K27 cold sides or bigger (AFAIK Doug, Mark, Tom, Greg?)

Any ideas what to use for the turbo to intercooler hose? Going out to take a picture, but I've blown off hoses left right and centre today.

My Intercooler to inlet pipe, turbo to intercooler, and the hose to the boost gauge :S

Needless to say, not my favourite pasttime, getting dizzy, lying under the car, putting hoses back on, front end off (again - got it down to less than 5 minutes now though, 6 minutes if the crossmember and intercooler need to come off) covered in crap etc.

Anyone have metal pipes? Any sort of flexible metal solution (sort of like the exhaust pipe Doug posted a picture of?) available? It seems the rubber pipes, under pressure, slide the clips along, so finally, one goes pop. You put that back on, and another goes pop... I can't imagine the Samcos will be any better in that regard, but at least they should be more resistant to splitting, that other age old bugbear.



Will post a photo of the pipe I mean... I know exactly what pipe it is when the car hunts for revs and tries to stall all the time. It's just a pita having to put the ****** back on every couple of weeks.. again...

PJ

[Doug_RS2]

Paul - is it that hose I sent you that is popping off? I ran that with RS2 spec boost and it never popped off!

Clean the surfaces with ipa and then use hairspray on the surfaces before you tighten it up - You can also use 2 jubilees on some of them.

I have made my own Turbo to IC hose using 2off 45 degree silicon hoses - these are actually reducer hoses as well - as I used a larger diameter metal T-piece. It was fine with over 2bar boost.

You can still use the samcos for the turbo to IC, Crossmember to metal pipe - these should be good.

[Markus]

What hose clips are you using? Almost all industrial applications use clamps like the ones below. Might be worth trying.

[Markus]

Second picture:

[Sidspud]

I found that some hose clips are a lot easier to tighten than others.
When I fitted my RS2 intercooler at Greg's meet, I/we had major problems tightening a hose clip with the end result that it fell off after 50 miles and I spent the rest of the night in the passenger seat of a flatbed doing 55mph up the M6.

But the next day, I took the hose off and swapped the clips from one end to the other and they were much easier to tighten. I have since been running without any boost leaks at all.

It could easilly just be duff clips or clips that you think are tight and aren't. I have to agree though that there must be a better solution to simply clamping them on as tight as you can. Unfortunately I don't know what the solution is...

[martinjs]

think they are 'mikalor' clips in markus's pics, deemon tweeks sell them.
just got my pipes from sfs today, im using a 52-63 45deg reducing elbow from turbo
then i'll just get a 63dia ally/stainless pipe with d/v take off then a 63-76 reducing 90deg elbow to the i/c (the outlets are 3") keeping all rest of intake tract 63mm.
as doug says i'd use 2x clips everywhere.

martin

[Markus]

The clamps in my pictures are made by ABA (see http://www.aba.se) and are called ABA Power Clamps. Another interesting alternative might be ABA's "Robust" range. They claim "High tightening force on thickwalled hose".

[audiman]

The joys of boost leaks!! I have had such a mare getting any of the pipes to stay on and not leak. So far i havent managed it. The IC to inlet pipe is the main problem one for me. I am going to have to make a different type of hose. More like the ABY one.

Paul, buy some new hose clips and lubricate the threads etc with some oil. This should make sure that they are tight. Some clips go tight, but the thread is the bit that is tight and not the clip!

Must sort mine out before long as it is starting to piss me off

[Sidspud]

Some clips go tight, but the thread is the bit that is tight and not the clip!

Thats what I was trying and failing to say!

[APNess]

Well, another day underneath the bloomin car, and it's all back together again. My solution was a complete and utter pig to get back on, it really was. I'm hoping that means it'll stay put for a while, till I can get a metal pipe made in the right shape.

Tom - I sympathise more now with your problems than before - as best I can theorise, the amount of air and pressure it's moving at 'pushes' the clips - even over the lip of the metal pipe, it seems. When it goes on, your sure it won't move anywhere, then Hisssssssssssssssss! ******

So here we have (picture attached) my lashed up nightmare to fit pipe. A real git to fit, but hopefully it'll sort me out.

We'll see. Vroom, Booooooooost! Hisss! ****...

Doug - you'll recognise part of the hose you sent - it just wasn't holding mate, so it's gone to a better place... Rest in pieces... well, ok, part of it is on the end of my metal/rubber hybrid pipe. If this pops off well... anyway, we'll see. It's physically impossible to get it off without taking the crossmember/intercooler off, that's for sure. Only thing to worry about now is splits...

[APNess]

Paul - is it that hose I sent you that is popping off? I ran that with RS2 spec boost and it never popped off!
I have made my own Turbo to IC hose using 2off 45 degree silicon hoses - these are actually reducer hoses as well - as I used a larger diameter metal T-piece. It was fine with over 2bar boost.

You can still use the samcos for the turbo to IC, Crossmember to metal pipe - these should be good.

I'm running RS2 spec boost too Doug, except on a 27 cold side

If it's not holding at the moment there's no way it'll hold when Mihnea waves his wand at it, and it's running what Tom runs.. (1.8 bar?)

If it *does* hold, I might tempt fate, take it off (uhhh, after removing the front end - again) and take it to a pipe fabricators saying "I want a pipe THAT shape!" before thrusting it at em.

Gotta see if it holds first *fingers crossed*



Paul

[S2 Ant]

Think Tom AKA Team Bodge will be impressed with that!!!

[Doug_RS2]

You still want a couple of lengths of silicon hose, even if you fabricate a pipe yourself - just to take up any movement in the car - Have you moved your snub mount bracket so it is hard down on the rubber snub mount - that might stop some engine lift, which could have been causing it to pull the hoses off. I would also check your engine mounts are tight as some people loosen them to lift the engine up to get the turbo out easier.

What Martin has done sounds very similar to what I have.

Martin will tell you what his jubilees were like at Gregs dads garage - leaks everywhere - partly becasue the jubilees seized when tightening - so you thought they were tight but they were nowhere near tight.

Paul - WAIT FOR THE SAMCOS - they will be better - especially with good clips.

[Keeper of The Kitten]

I'm guessing the really robust solution would be to use hard pipes with wiggins type quick release clamps? Steel ones are available for hot bits!

__MDC__

[newsh]

Paul, absolutely essential to grease the threads of the clips, you will easily be able to do them up much tighter if you do, proved this on a few of our cars at the garage meet.
Test.
Do the clips up as tight as you can with a screw or nut driver, put a couple of bars of pressure on with the tester, listen to them hiss, loosen them off, grease the worm and thread of the clips, tighten again, add pressure, no hiss.