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Lately I've been brainstorming how I'd like to run my intercooler piping for my L28ET S30, and I've come up with (what I think to be) a unique and simple solution that should do everything that I'm trying to achieve. Firstly, let me state my goals: 1.) Keep all the piping on the left side of the radiator. This means both intercooler pipes and intake. I am running a Treadstone intercooler with same side inlet/outlet tanks. 2.) Allow the removal of piping in the engine bay, without having to touch anything in front of the rad support. Not really a big deal, but it would make servicing and pulling the engine easier. 3.) Maintain or increase the rigidity of the rad support. This is the big one, I do NOT want to simply cut larger holes in the rad support. I am looking for strength, simplicity and cleanliness here. Problems: I'm working with three different sizes throughout all my components. My intercooler has 2.5" outlets, my TB has a 3" inlet (manifold has been ported, before anyone tells me that it's a waste) and the turbo has a 2.5" outlet and a whopping 4" inlet (Holset HY series). In an ideal world, these values would be much closer together, but this is what I'm working with. I plan on using a reducer hose to immediately drop the 4" inlet to 3" and keep everything between the filter and turbo 3". The piping between the intercooler and turbo outlet is the only two parts that match, so these will obviously be 2.5" In between the TB and the intercooler I plan on using both 3" and 2.5" piping, joined by a reducer at the rad support. This may not be best, but I've already got the 3" portion being built, and it's going to be a work of art so it's staying! Whew! Now to my proposal! I would like to weld in steel joiners directly to the radiator support. My thinking is that this would avoid any loss of rigidity typical to cutting large holes and possibly increase it over stock. All I'm adding is one additional silicon connection per pipe with this set up, which shouldn't create any noticeable loss in flow. Here is a picture of a joiner, and two (admittedly poor, I'm away from any graphics software) hand drawn illustrations to demonstrate exactly what I'm getting at. Has anyone ever done anything like this? Are there problems with this sort of set up that I'm overlooking? Thanks for reading what has unintentionally turned into a rather long winded post! Discuss...
