So after seeing quite a few at the last nano meet i decided to take a good look at the intercooler (bend) outlet pipe stub as we know it consists of being held in by a bolt ajoined to the radiator and is pushed into the intercooler housing at the bottom of the radiator, the bend as two o-ring fitted to it which gives it the seal once pushed home, these can fail so i was wondering for added security and a better seal why not add a third below you will see my findings.
This first photo shows i have cleaned the intercooler bend and you can see the space for the O-ring which is last when pushed into the cooler, next is another section with four plastic bridges the center part and the we have the end of the pipe where the first ring would and should sit. Fig 1
I thought if i was to cut out the centre plastic bridge x 4 round the pipe it would enable me to add another ring so i cut it out Fig 2
When cutting i made sure i only cut to the depth of the O-ring and cut both sides of the bridge Fig 3
Once i had cut all four to the depth needed i then cut out the nib of plastic left with a stanley knife held at an angle Fig 4
When i had cut out all four i then used the edge of a file to smooth down any remains of the plastic bridge so the center looked identical to the first inset part of the intercooler pipe Fig 5
The pipe is now ready to have the O-rings fitted as you can see i use an hook for this Fig 6
First fit the last ring onto the bend making sure it is snug and only use Viton rings Fig 7
Next fit the now new centre O-ring where the plastic bridges have been cut out Fig 8
The next step is to fit the first O-ring which will be pushed into the intercooler and lies on a leadge inside the intercooler recess this is the first ring which as been known to swell and blow Fig 9
The intercooler pipe is now ready to be fitted hopefully giving a better seal than with just two O-rings in place i have only modifed one these which needs to be tested yet, but i can not see why this should not work.
Maybe even if need be leave out the first O-ring leaving only the center and last O-ring which then the pipe should push in a little further i yet have to make sure and will report back cheers Arctic.
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