Intercooler Pipe Modification/clearance Issues - Advice Needed

[nismo_au]

Hi all,

Just looking for some advice with a little problem I have with front bar/intercooler pipe clearance. I currently have a HKS intercooler kit and GTR front bar fitted to my car and the return pipe from the core interferes with the front bar drivers indicator slots. To get around this I have done what many others seem to have done and sand back a small portion the front bar to accommodate this return pipe, although as a result have made it impossible to fit GTR indicators (see picture).

I am going to replace this front bar very soon with the same style GTR bar and would like to avoid cutting the bar to allow the fitment of the GTR front indicators and avoid pipe sticking out. One way I can see getting around my clearance problems is to shorten the U-bend intercooler return piping by about 4cm, after measuring it all up cutting the pipe it would allow just enough clearance without requiring modification to the front bar. My only concern is if I cut 4cm of the pipe I will lose the raised "lip" on the end of the pipe and am worried if this is removed will I be asking for a leaking intercooler pipe or having the pipe come off under boost? This "lip" is obviously there to help prevent the hose clamp/silicon pipe from shifting under boost.

I can't see any other way around this problem apart from cutting the pipe, getting a new U-section fabricated (don't know how much this would cost) or just modifying the bar and living with intercooler pipe slightly protruding from the from bar. Can I get away without the lip on one section of the pipe and still get a sealed connection between the intercooler pipe and silicone hose with hose clamps alone? Any ideas or advice?

[mad082]

can you slide the pipe a bit further into the joiner, or even get the pipe cut a bit shorter. can you mount the cooler closer to the radiator?

[nismo_au]

can you slide the pipe a bit further into the joiner, or even get the pipe cut a bit shorter. can you mount the cooler closer to the radiator?

Unfortunately the pipe is as far as it can go into the joiner and can't mount the cooler any closer to the radiator. It seems the only options are to cut the pipe so it can fit closer to the joiner or cut the front bar so the return pipe sticks out a little bit. But as I said cutting the intercooler pipe looks like it will work but will cut off the raised lip on the end of the pipe in the process and as a result may cause leaking pipes under boost. Does anyone know if this is the case or is it possible to get a new lip machined on to the shortened pipe?

[mad082]

you could always get a bead welded onto the pipe to stop any chance of the pipe coming out. doesn't even need to go the whole way round. just 3 or 4 welds about an inch long at oposite sides will be enough.

[nismo_au]

you could always get a bead welded onto the pipe to stop any chance of the pipe coming out. doesn't even need to go the whole way round. just 3 or 4 welds about an inch long at oposite sides will be enough.

Yeah that might be the way to go. Cheers for your help!