DIY eBay Intercooler + Piping

[SoFresh]

Okay, I've noticed that there are a few fellow audiziners out there looking for the inexpensive route to go, here you go. I bought my piping on ebay, as long as the t-bolt clamps, and couplers. I went with a 45 degree bend coupler to connect from the trottle body down to the intercooler piping, that was $35 off ebay. I decided to go with hump couplers as well instead of the cheap couplers some sell on ebay. The couplers can be found online from a company called: HighTempSilicone. The core was also purchased on ebay as well. Everything took about 3 hours to setup, you just need some paitence. Also the bracket was made from pieces of steel from my local hardware store for about $7. I would recommend going with aluminum pieces instead however so they dont rust. I had to paint mine with flat black rust paint about a week after installation. Looks good now however, I also suggest painting it black anyways so you cant see it through your grill. I have the RS4 grill, so it showed through.

I forgot to take pictures of in the process, but here are some pics after the installation. I did this about 4-5 months ago. I also went with a smaller intercooler so I wouldnt have to cut the bumper support bar. I used 2.5" aluminum piping, however lost a little boost since I still am currently rocking the crap out of the K03, I would suggest if youre still K03, go with 2.25" piping.

Overall I spent around $300 for the entire thing.

Enjoy. Sorry about the low quality pics, they're from my camera phone.

[Poopie]

hows that look with the bumper on? good job by the way. Do you think you can get a list of bends you will need?

[Aliel]

Where did u get the T-fit for the blow off valve and the hose for the intake manifold?

[SoFresh]

Here is a list of the bends you need in the piping, you do not need an entire kit.

(2) 90 degree bends
(2) 45 degree bends
(2) 75 degree bends

.... actually I still have 2 pipes left over, and I dont remember which ones, so you might only need 1 45 degree bend, and 1 75 degree bend. Its been a while, so I dont remember. Order a kit with those bends and youll end up having 2 pipes left over. I actually emailed one seller on ebay and gave him a custom order, and he next day delivered everything for only $75 for the total cost.

[SoFresh]

Where did u get the T-fit for the blow off valve and the hose for the intake manifold?

The silicone bend is a 45 degree bend coming off the TB, actually it was one huge long piece, but I spliced the T pipe in there for the BOV, which isnt needed, so you'd be fine buying one 45 degree bend silicone hose. I bought it als from HighTempSilicone, however I have also seen them on ebay these days. I just was picky and wanted it in red and there was none on ebay in red at the time, lol.

I actually have 2 T-pipes for sale in my link in my signature, one for a HKS SS BOV, and another for a Turbo XS BOV, you can also purchase the BOV's with them from me as well.

[1 ate T]

Sweet. I'll probably do this within the next month

[SoFresh]

I bought my core from a seller on ebay under the name: just-intercoolers, then for an additional $75 he added in all the piping I needed, even asked me if I needed couplers, but I had already bought them in advance from HighTempSilicone.

Side note, I did have to trim up my front bumper, I have the Rieger RS4 front bumper, so I did do some trimming, actually alot of trimming.

[zrowcool]

Does it run rich with the BOV and the MAF connected or is that deleted some how.?

[SoFresh]

Does it run rich with the BOV and the MAF connected or is that deleted some how.?

Yes it did run a little rich, but never had any issues to be honest. I did however reciently add the 710n DV and took off the BOV, these pictures were just taken before I made the switch. I have the BOV for sale in my link in my signature. There are two BOV's for sale.

[zrowcool]

any reasons for switching or were you jsut tired of the setup?

[SoFresh]

any reasons for switching or were you jsut tired of the setup?

Looks cleaner and got a 710n DV for cheap, also I kinda got tired of hearing the loud pssshh sound. If you are looking for a really loud sound, go with the HKS SS BOV, if you want a really deep and long swwwwuuushh sound, go with the Turbo XS RFL, Im selling both of mine as of now. Ive had BOVs on the last 3 cars ive owned... just want some change and quietness.

[bass_lover1]

I dont think you mentioned this, but what size core are you using? I notice a lot of the ebay cores are all of similar size (mostly really thick and long), I dont plan to go larger than a K04 so I dont need huge, I'm looking for like 20"x6"x2.5" core sizes...which would put overall length at like 26-27, I'm hoping yours is similar cause if so I know I can get that to fit my Passat w/o issues.

Thanks man.

[SoFresh]

The overall core size I went with was: 27"x6"x2.5", and the inlet and outlet were 2.5". I am very pleased with the quality. The core cost me $56.00 with BIY on EBAY and shipping UPS ground was $31.00 from the seller: Just-Intercoolers

[1 ate T]

This one?

http://cgi.ebay.com/ebaymotors/FMIC-...spagenameZWDVW

Guy has 100% positive feedback

[SoFresh]

This one?

http://cgi.ebay.com/ebaymotors/FMIC-...spagenameZWDVW

Guy has 100% positive feedback

Actually that one is very close, but looks a little different, it should work however. Here is the pic from the auction I won. Item #230032555962




The quality is much better looking in person. FYI

[1 ate T]

nice, I may do this sooner than I thought... It's very cheap.

Plus the 100% feedback makes me feel comfortable..

[SoFresh]

nice, I may do this sooner than I thought... It's very cheap.

Plus the 100% feedback makes me feel comfortable..

Yeah the seller was a nice guy, he forgot to ship out the piping with the intercooler and he personally called me and then threw in some extra goodies and also overnighted the piping to me asap. Very great customer service.

[1 ate T]

lmao I just bought one.

Do you have a pic with the bumper cover on?

[SoFresh]

Yeah, I got some pics somewhere, let me try to dig them up somewhere, Ill post them as soon as I find them with the Rieger RS-4 cover on.

[Aliel]

I just want to relocate my DV to the cold side so I would need some different kind of T. It should be one with a flange for the hose that connects to the DV. Do you know where I can get one of them?

The silicone bend is a 45 degree bend coming off the TB, actually it was one huge long piece, but I spliced the T pipe in there for the BOV, which isnt needed, so you'd be fine buying one 45 degree bend silicone hose. I bought it als from HighTempSilicone, however I have also seen them on ebay these days. I just was picky and wanted it in red and there was none on ebay in red at the time, lol.

I actually have 2 T-pipes for sale in my link in my signature, one for a HKS SS BOV, and another for a Turbo XS BOV, you can also purchase the BOV's with them from me as well.

[SoFresh]

I just want to relocate my DV to the cold side so I would need some different kind of T. It should be one with a flange for the hose that connects to the DV. Do you know where I can get one of them?

Ebay probably, you just need to figure out the correct word to search on there.

[lude2euroa4]

imo, i think its gonna look like shit with the left side piping not level like the other side, it looks cheap...

i had to whip out a grinder and cut away at the plastic near the ac hoses to make it perfect, i did mine twice the first time i left it looking like shit the second time i took my time and i think its a perfect fit..

[europshhrc279]

im really looking into this ...might get one very soon aswell...so far i found a piping kit with couplers and all that for 75 bucks plus 30 shipping but its all 2.5 inch piping...would that be ok? also the cores ive found from just-intercoolers all have 2" inlet and outlets...can you run that size with the 2.5 inch piping? or should i find one with a 2.5 inch inlet and outlet to match the tubing? im looking to order the piping and core very soon so some help would be great

[AudiSport12]

i think 2.5 may be a little much for the k03, but if your looking to go k04 you might be fine. someone please correct me if im wrong.

im also really looking into doing this as well...

[europshhrc279]

by the way AUDI ENVY thnx for the new desktop wallpaper pic of your car ;)

[europshhrc279]

eh not so sure about the KO4 so i guess id have to find 2.25 or 2" which i cant find on ebay =(

[lude2euroa4]

^^ u can definetly find nicer pics then that one, ill take some nicer ones when it gets warmer...

as far as 2.5 on k03, your going to loose like 1 psi if that, im using 2.5 piping with 2.5 inlet outlet on the intercooler, also if you wanted to get core with 2.0 in/out you can get couplers that change in size example 2.0>2.25 or 2.25"2.50

i actually forgot what my size piping is 2.25 or 2.50? ill check on it tomm.

[SoFresh]

Go with 2.25" or 2" piping, you can email most ebay sellers and have them put a kit together for you.

[SoFresh]

imo, i think its gonna look like shit with the left side piping not level like the other side, it looks cheap...

i had to whip out a grinder and cut away at the plastic near the ac hoses to make it perfect, i did mine twice the first time i left it looking like shit the second time i took my time and i think its a perfect fit..

I dont think mine looks like crap, most people complement mine, but thats just me. Most all premade kits bend down on the left side as well. So you'd be calling all the expensive kits crapy looking too. I prefer to not half to hack up the left side to make it straight, but it does look good. To everyone their own.

[AudiSport12]

lude, where did you get your FMIC? what are the dimensions of it? did you have to trim? the main thing i am worried about is having to hack up my brand new S4 bumper. also, im guessing the piping forces you to get rid of fogs.. damn

[SoFresh]

lude, where did you get your FMIC? what are the dimensions of it? did you have to trim? the main thing i am worried about is having to hack up my brand new S4 bumper. also, im guessing the piping forces you to get rid of fogs.. damn

Im pretty sure Lude made his own kit. If I remember correctly there are pics somewhere on audizine of the piping.

Side note... youre going to have to cut up any bumper you have to fit a FMIC.... unless its like 1.5" thick..., even then I could see some cutting. Cutting isnt all that hard however, you could also use a good power sander to shave off some room for fitment. Thats wat I used, because the Reiger RS4 front bumper is plastic.

[1 ate T]

I'm PMed the seller for piping. I will do pics and a writeup of the install

Thanks for the inspiration lol

[lude2euroa4]

my core came from BranCKY piping and couplers i bought from 2 diff sites, forgot the address's.... i did all the fitment myself, cutting the s4 bumper was minimal, i had to cut a few tabs from the back which smotthed out the shape of the back of the bumper so the tabs wouldnt poke the fins in the core.

i could probably HAVE installed s4 fogs but i removed the bars from the side grills that held the fog housing, i might get micro de's one day and install them like BASSED did.


just to post on how it DID look and now how it does look, my opinion is before sucks after is veryyy Niiiiiice

[1 ate T]

Yeah I will probably be working on it for A WHILE to figure out how to make the pipes straight.

Looks good man. And you have Kamei with stock rings like me

How'd you attach your rings?

[ct1.8t4me]

What is the diameter of the K03 turbo compressor outlet? I tried to search but didn't find anything.

Thanks.

[d_maniac]

high_octaneRS-4 did you have to get rid of the fogs to fit the foglights in??

[d_maniac]

lude2euroa4 how did you get the pipes so straight from the before pics??? Did you cut the piping too??

[SoFresh]

high_octaneRS-4 did you have to get rid of the fogs to fit the foglights in??

I removed the fogs and sold them way before I did my FMIC, also I have the RIEGER RS4 front bumper, so therefore, I have no foglights, however, you could put some aftermarket fogs down there, but the stock ones wouldnt fit.

[lude2euroa4]

lude2euroa4 how did you get the pipes so straight from the before pics??? Did you cut the piping too??

doing a fmic, its fully custom i cut pipes, i cut some plastic from the front of the car, it took about 3-4 hours but i took my time and im am very pleased with the finished product. i also sprayed the pipes so they dont rust in the future...

the person who i owe tons of credit to is kompressed he walked me through the install, hes an swesome dude.

[lude2euroa4]

i only used 4 couplers even though i bought 8, i cut the pipes so that i only had to use 2 pipes on each side, i played around with the pipes and before cutting any of them i mapped out where i would make cuts, i first would start with the piping coming out of the intercooler so it had the level straigh across look, then i planed the other pipes on the cold side and hot side.

RS4 your a good guy nothing against you BUT please do it over, its going to look much better and you wont regret it, take your time and map out the piping