Thread: TD5 Silicon hose routing UPGRADE?!!

Evenin’ guys,

After reading up about ‘the’ silicon hose discussions on the forum, I wanted to know more about the pro’s and con’s of changing to silicon hoses and decided to take a wee trip up to Hornsby this afternoon to chat to the very friendly chaps from TurboXs a few of you have mentioned on the forum.

Essentially, it is pretty easy to exchange the standard rubber hoses for silicon jobbies, but to me, if I am going to change anything, I want it to be better than it was. In this case, I was looking for (possible) better performance with better reliability.

Just to keep objective about the discussion I had, I had an open chat to these guys, have no vested interest in the discussion, other than that I believe the factory standard set-up can be improved upon…….and would like to do so for my own TD5.

After an hours worth of banter and poking our heads under the bonnet of my Disco II, we came up with the designs below to simplify and improve the airflow from the turbo through the (standard) intercooler to the inlet manifold. Eventually, when $’s allow, I would like to fit an up-rated intercooler under the bonnet, but until then, the below mod could be the in-between step…

What do the drawings for the proposed design say:

Turbo to Intercooler pipe:

1) Replace the first 90 degree bend with a silicon one.
2) Replace the standard metal pipe with the longer mandrel bent and flanged ended pipe (incl. the little nipple for the boost pressure controller).
3) Loose the 90 degree bend at the end of the existing metal pipe (didn’t know how else to describe it).
4) Replace the final 90 degree bend to the intercooler with a milder 45 degree bend silicon jobbie.

We have purposely decided to leave two silicon bits in the design here, as this would leave some amount of flex in the new design.

Intercooler to Inlet manifold - this was the ‘challenging’ side….:

1) The original 90 degree rubber bend is replaced by a milder 45 degree silicon bend.
2) This feeds into a pipe that is flanged at the end to match up to the bore diameter of the inlet manifold.
3) A new ‘bit’ is CNC machined that is at a significantly greater angle (downwards) than the standard EGR valve or direct replacement pipes that are available. This will be much shorter too.
4) A short bit of straight silicon hose (read – much cheaper) is fitted between the pipe and the EGR replacement piece.

This may change a little when the first prototype is made, as the mandrel bent pipe may be able to handle the 45 degrees that the silicon hose was going to make and thus a straight bit of silicon hose could be used.

OK, now the hard bit ……. what will the kit cost:

1 x 90 degree elbow
2 x 45 degree bends (may be 1 x + 1 x straight bit)
1 x pipe length required
1 x mandrel bending of turbo to intercooler pipe
1 x welding nipple onto turbo to intercooler pipe
2 x flange turbo to intercooler pipe
1 x flanging intercooler to inlet manifold pipe
1 x flaring intercooler to inlet manifold pipe
1 x new CNC machining EGR replacement pipe
1 x flanging EGR replacement pipe
8 x ‘silicon hose’ T-clips

1 – 5 buyers : A$ 450
5 -10 buyers : A$ 350
10 – 15 buyers : A$ 320
15 – more buyers : A$ 300.

What I would like to know is the following:

A) What do you think of the design? Please shoot holes in the design if there are any REAL holes to be had…..
Is the design for a Defender the same as for a Disco II like mine?
C) Who would be interested to buy with me – I will get the ugly demo version and will pay the same as everybody else. Payment would be DIRECTLY to TurboXs & excl. shipment – can’t imagine that this would break the bank though!

Cheers,

Auke

P.S. Please excuse my less then 3 year child level of drawing. I get paid to yak & not draw.....

Afternoon Ciapek,

The thing I was thinking of should be UNIVERSAL....

However, I am not sure how the routing from the Turbo to the intercooler and fom the intercooler to the inlet plenum is on the Defender....

I can't imagine that it will be all THAT different, but they are made by Land Rover of course....

I have checked my RAVE CD and unless i am mistaken, I do NOT think there is a difference in the engine set-up as described above, I do believe that the airbox is in a completely different location and that the (cold air) input to the turbo is different, but between the turbo to the inlet mnifold looks the same.

How does your lay-out stack up against the sketches posted above??

Auke