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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 November 27th, 2012, 19:37   #1
Fix_Until_Broke
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Default Turbo to Intercooler Pancake Pipe Replacement - ALH

I've done nothing with my Turbo to Intake despite many people insisting that it's a limiting factor. I have never liked the pancake pipe so decided to build one while I had some time off over Thanksgiving.

I didn't want to cut the OEM hose end off the turbo outlet hose, so I decided to make a mating part to it. I started with a ~3" long piece of 2" dia x 0.065 wall steel tube and expanded it out to fit snugly over the hose end. The flange was simply bent over with a hammer and the cuts for the tabs and clip were done with a cutoff wheel. It looks fancy, but didn't take all that long.








Here's a shot to show how snug it fits over the hose end


I used one 90 degree 2 inch diameter tube from Woolf Aircraft for $20. They are the only place I've found that does 1D CLR mandrel bends (a 2" tube has a 2" Center Line Radius).

I cut the tube in the middle of the bend to get it to mate up with the hose adapter and run along the side skirt.


And then tacked it to the adapter


Then I took the rest of the 90 degree bend, cut it some more so it made the bend to the intercooler inlet. I shoved the long leg into the intercooler inlet (it fit snug) so it was lined up well.


Once I had that tacked together, I trimmed the leg to length and expanded it out to slide snugly over the 2.5" diameter OEM hose on the intercooler inlet.


After I had it all mocked up, I compared it to the OEM one and then welded it up.




Here it is all welded up and ready for paint
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Old November 27th, 2012, 19:37   #2
Fix_Until_Broke
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I painted it with VanSickle "Super Premium" enamal spray paint which is really good stuff, but takes a minimum of 24 hours to dry per coat.



Looks pretty nice all painted up if I do say so myself...


It took longer to remove/replace the tire than it did to install it






Tire Clearance at full lock with 205/70/15's


It has not blown out with some spirited driving up to 28 PSI so that's a good start.

I can't say I notice any difference in performance, but I'm reasonably sure it's not hurting anything.
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Last edited by Fix_Until_Broke; November 27th, 2012 at 20:08.
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Old November 27th, 2012, 20:25   #3
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Looks great! Now do the upper pipe and upgrade the intercooler
That reminds me... I need to mail something to you.
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Old November 27th, 2012, 20:33   #4
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Looks awesome! Good fab skills!
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Old November 27th, 2012, 21:06   #5
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Nice work. Like the connection you fabbed up.
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Old November 28th, 2012, 07:10   #6
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Yes, nice work!
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Old November 29th, 2012, 10:01   #7
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Nice work. Any interest in making another one?
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Old November 29th, 2012, 10:13   #8
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Very nice work.
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Old November 29th, 2012, 18:13   #9
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"I can't say I notice any difference in performance, but I'm reasonably sure it's not hurting anything."

Any chance you notice the turbo spools quicker now than with the oem pancake pipe?

df
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Old November 29th, 2012, 19:50   #10
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Thanks for the kind words everyone...

Maybe someday I'll do a bigger SMIC or upper pipe but those are not as restrictive as the pancake pipe is in the whole scheme of things.

I could probably make another one in much less time than this one took (I've got about 6 hours in it) and it would probably look better as well. We'll see - the adapter is the tricky part, the bends and intercooler connection are pretty easy. Maybe I can make a couple up over christmas if I get time.

I have not noticed any quicker spool or anything different with this new pipe - If I didn't do it myself I wouldn't know it was there.

The only things that have ever made any noticable power changes have been fuel and tune - everything else has been "because it seems like a good idea".
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Old November 30th, 2012, 06:13   #11
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I got a noticeable change in the audible noise coming from the 17/22 under boost at RPM's less than 3500(ish) when I installed my 1.8T Pancake Pipe. Course the 1.8T pipe is flatter, maybe that flat surface area has something to do with a resonating metallic noise?
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Old November 30th, 2012, 08:40   #12
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Very nice!
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Old November 30th, 2012, 09:16   #13
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Good job
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Old November 30th, 2012, 09:26   #14
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very nice!!
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Old November 30th, 2012, 11:21   #15
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Quote:
Originally Posted by Fix_Until_Broke View Post
...
I have not noticed any quicker spool or anything different with this new pipe - If I didn't do it myself I wouldn't know it was there.

The only things that have ever made any noticable power changes have been fuel and tune - everything else has been "because it seems like a good idea".

Thanks for the honesty.

df
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