INTERCOOLER
Here's the blow off valve I decided to use. It looks great, but one thing I didn't like about it was the way it was supposed to be mounted using a piece of rubber hose. So without spending a heap of cash on a Blitz or HKS valve I decided to redesign the mounting for the Excess Valve.
A nice looking valve let down by the look of a rubber mounting hose…
I made the intercooler pipework from stainless steel tubing. First I machined the barb off the end of the blow off valve and then turned down a piece of stainless steel shaft for the blow off valve to neatly fit into. Not shown is an internal groove that I made for a "O" ring to achieve a perfect seal. The blow off valve is held in using three stainless steel grub screws around the outside of the sleeve.
Next step was to position and tack weld the pipework together. I did this using a TIG welder.
Once fully welded, finally I smoothed all the welds down and polished the stainless tubing.
This is the EVO 5 intercooler. It fit nicely in-between the headlights. It's a bit hard to see because of the dark blue paint and black radiator. All intercooler hose connections are silicon based to withstand the heat of the turbo.
