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TDI Power Enhancements Discussions about increasing the power of your TDI engine. i.e. chips, injectors, powerboxes, clutches, etc. Handling, suspensions, wheels, type discussion should be put into the "Upgrades (non TDI Engine related)" forum. Non TDI vehicle related postings will be moved or removed. Please note the Performance Disclaimer.

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Old October 30th, 2011, 17:59   #1
FirstOrbit84
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Default The <$100 Lower IC pipe (pancake pipe) upgrade

Hey folks! I just wanted to share how I upgraded my pancake pipe today with an OEM one from a 1.8T... Basically, I'm trying to do all of the supporting mods before I spring for a turbo (or if I don't buy the turbo, I'll end up as the fastest VNT-15 ). So, I'll be doing IC piping, intake piping, upgraded SMIC, race pipe, EGT gauge, downpipe... and then 17/22...

I started by looking at the piping set from ID parts, but at $155, I felt I could do better.

Then I found a couple articles on UK-MkIVs that got me inspired:
http://uk-mkivs.net/forums/p/193681/1302951.aspx
http://uk-mkivs.net/forums/p/194729/1263970.aspx

So, I picked up a used 1.8T pancake pipe from VWVortex for $35 shipped, and I bought about $60 of supporting hardware from http://www.frozenboost.com/ NAPA, and Advance Auto Parts:


UPDATE: This mod can be done much cheaper and easier by simply getting a 2" diameter hump hose connector; trim about 1/4" of length from each side, and attach one end to the pancake pipe, and the other end to the metal connector of the stock turbo outlet hose.

The parts I needed from FrozenBoost were:
2" to 1.375" silicone reducer
2" stainless steel joiner
1.375" stainless joiner
2" T-bolt clamps
(I also bought a 90 degree 2" section but did not need it, so I will use it on my custom air intake.)

Then, I got a 2" section of hose from NAPA that had several bends that looked useful, and two worm hose clamps from Advance Auto for the smaller piping. Plus, I was given an extra stock early style turbo outlet hose from a local friend/TDI guru.

First I jacked the car up, put it on jack stands, removed the skid-plate, front passenger wheel, fender liner, and passenger side engine skirt:


Then, I took out the old pancake pipe and compared the two:



Then, I chopped the 90 degree elbow off the stock turbo outlet hose, and attached it to the 1.375" stainless joiner with a worm hose clamp (not shown):

Then I put that section back on the turbo outlet on the car because it was easier to work with like that.

Then I cut into the rubber hose from NAPA to get the angle that I needed, and attached that to the 1.8T pancake pipe with a worm clamp, and then to the 2" stainless joiner and then to the 2" to 1.375" reducer with t-bolt clamps. I tried to match the angles of the stock piping as best as I could:


Then I fit the whole thing on the car, and tightened all the clamps, and took her for a test drive!

Once I was sure that the boost was holding well, I came back to button everything up by putting the engine skirt on, fender liner, and skid plate.

In situ:


I definitely noticed a good amount less turbo lag, and there should be a bit more top end power in theory, but I couldn't really tell much of a difference in overall power.

Next will be race pipe, custom intake piping, and then, ebay SMIC!
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Last edited by FirstOrbit84; November 26th, 2011 at 21:43.
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Old October 30th, 2011, 19:13   #2
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Nice. Thanks for sharing!
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Old October 30th, 2011, 19:19   #3
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Did the IC to pancake pipe have to be changed or can that stay the same. I may end up doing this mod next weekend as I already have a 1.8t pancake pipe set aside for it.
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Old October 30th, 2011, 19:22   #4
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I'm curous as well.

I have a 1.8t stock pancake pipe (around here somewhere) and am wondering what it will take, then the next issue will be possibly clearing my DG metal sideskirts.
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Old October 30th, 2011, 21:15   #5
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Thanks so much for the how-to, subscribed.
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Old October 31st, 2011, 03:38   #6
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Quote:
Originally Posted by CT TDI View Post
Did the IC to pancake pipe have to be changed or can that stay the same. I may end up doing this mod next weekend as I already have a 1.8t pancake pipe set aside for it.
Nope, the other end of the pancake pipe fits right into the stock intercooler connection, they are both 60mm IIRC. I believe our stock IC is the same as the 1.8T IC.

also wanted to mention:
the elbow from the inlet end of the pancake pipe to the reducer should be approximately 30 degrees to 45 degrees. the bend at the end of the stock turbo outlet hose is 35 degrees, but i found out that the inlet end of the 1.8t pancake pipe is at a slightly different angle.... that's why i ended up going with the 2-ply rubber hose from NAPA as opposed to a 30 degree or 45 degree 4-ply coupler: because it was more flexible, and had the right sort of a bend and twist that i was looking for...

another method would have been to weld a reducer on the 1.8t pancake pipe, but the quotes i got were in the same ballpark as the cost of all the couplers, and now if i do upgade the turbo later, i can just change the reducer size to match the new turbo outlet.

also, you want to remember to transfer the rubber insert at the hanger from the old pancake pipe to the new one, if yours does not have one already.
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Last edited by FirstOrbit84; October 31st, 2011 at 03:43.
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Old October 31st, 2011, 04:16   #7
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did this a while back but because my turbo was reclocked to fit the stock piping it made it a bit more of a pain. but if your using stock turbo this isnt a bad how to . you deffinatly notice an increase in response not sure about anything else but definatly seems to respond instantly now
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Old October 31st, 2011, 06:10   #8
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Quote:
Originally Posted by FirstOrbit84 View Post
Then I fit the whole thing on the car, and tightened all the clamps, and took her for a test drive!

I definitely noticed a good amount less turbo lag, and there should be a bit more top end power in theory, but I couldn't really tell much of a difference in overall power.
Do you have an EGT gauge? Any noticeable drop in EGTs? Even if the mod doesn't give any power gain(s), it may help lower EGTs, important for future mods you have planned.

Good luck.
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Old October 31st, 2011, 06:35   #9
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how does this mod actually help please? it looks to be larger volume, so how does this reduce lag? This is an intake pipe from the intercooler or into it? (I have a Passat, not Golf, just curious)
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Old October 31st, 2011, 07:08   #10
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This is the inlet side of the intercooler from the turbo on our cars.

I am also wondering how this would reduce lag. I can definitely see the top end gains from more flow, but it does seem to me that a restriction there would help spool up a little bit faster.
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Old October 31st, 2011, 08:58   #11
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No EGT gauge. I do have a scan gauge so I can see intake temps at the IC, and they didn't look too much different, if at all.

This pipe goes from the turbo to the intercooler.

I'm not sure if I'm correct on the theory behind why there would be less lag, but I believe the spool up is a function of boost requested by the ecu (which is a function of throttle input and tuning) and engine speed (and therefore exhaust flow available to spool). By opening up the path from turbo to intercooler your boost gets to the intake quicker and more efficiently, producing less lag and overboost. Someone please correct me if I'm wrong.
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Old October 31st, 2011, 13:48   #12
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I have the 1.8t pancake pipe with the lower intercooler hose from idparts.

Hooked right up to the 17/22 I'm running. but I had to weld a 2.5 inch inlet on the pancake pipe.

Got my 1.8t pipe off ebay for under 20 buck IIRC. Still under 100 bucks total.

Pictures in this thread
http://forums.tdiclub.com/showthread.php?t=300211
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Old October 31st, 2011, 13:55   #13
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If Isonic ever gets me some of the pics he took I'll post them up. I turned a custom reducing coupler for him, he put a 1.75" elbow off of his 17/22, through my coupler to 2" either 30 or 45 elbow right into the pancake pipe.

Boost definitely comes on sooner. If people thought a 17/22 sounds funny, a 17/22 with a 1.8T pancake pipe sounds like rape.
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Old October 31st, 2011, 18:03   #14
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Quote:
Originally Posted by JFettig View Post
If Isonic ever gets me some of the pics he took I'll post them up. I turned a custom reducing coupler for him, he put a 1.75" elbow off of his 17/22, through my coupler to 2" either 30 or 45 elbow right into the pancake pipe.

Boost definitely comes on sooner. If people thought a 17/22 sounds funny, a 17/22 with a 1.8T pancake pipe sounds like rape.
Yeah the 17/22 has a distinct sound. Then when a 1.8T pancake pipe is added it does sound pretty cool. Here are the pictures Jon was talking about:








Every thing is 2" except for the 1.75" 90 degree elbow that connects to the 17/22 outlet. It is a tight fit but it doesn't rub on the block and it sounds way better than the stock piping. Plus, being from a 1.8T, it can NeVaR lose ;-)
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Old October 31st, 2011, 18:14   #15
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cool, ya you have a couple less connections compared to mine...

in the last pic, it looks like it was rubbing on your axle a bit...
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