Boost pipes keep slipping off

[casperjjordaan]

Hi guys.

I am having a problem with my boost piping. On my 1.9TDI ASZ 9N polo, I use stock inter cooler, but the piping has been changed to stainless pipes and silicone bends. Now, under on the inter cooler, the god-forsaken 90deg silicone bend keeps slipping of the inter cooler. Resulting in......no boost! I used proper boost clamps, but it does not hold the silicon bend on the inter cooler. Please help me! There is no money for FMI and all of that jazz. I need to fix this.

Here is me Sunday evening at 10pm stuck on the N1 at Rigel. Slipped off boost pipe, yet AGAIN!!

[MarshallGTi]

Genkem contact adhesive, and clamps need to be f0kken tight

[M@rk]

Hi Casper

Jy moet n lip laat flare op die boostpype , of makliker weld n ridge om die stainless steel boost pype en dan behoort hy nie af te kom nie , en ek hoop jy gebruik T bolt clamps.

Het al 2.7 bar geboost en hule kom nie af nie.

[Jueshen]

try get some grooves on the stainless pipes so the silicone can grip, apply thin coat of sunlight liquid it will help slip the pipe on when just applied and when hot it gets sticky.

[casperjjordaan]

Thanks guys. Where the silicone hose goes over the stainless it is sorted out now. I used double boost clamps on every joint. My problem now is mainly where the silicone hose goes over the intercooler. And yes, the intercooler is plastic, so in cannot be clamped like hell-o-va tight. and the fooken thing keeps coming off! HELP ME PLEASE!!

[BIGMIG]

Can you share a pic of the inter cooler?

My fix is to
1: Make sure that the hard pipe (metal) has a bead on the end where the silicone pipe will fit over.
2: Lightly run a rasp over the outer wall where the metal meets the silicone. Don't run the rasp over the bead but rather after it, in the same place where the boost clamp will tighten. This creates tiny rough spots for the silicon to bite into.
3: Clean all oil off of pipes and apply light coating of hair spray where the pipe will join. (I have had success with the first two steps and so have never had to use this step.
4: Use worm gear clamps preferably Norma as they have an extra springy band that helps to stop the clamp from loosening itself and creates a better uniform sealing ring. These clamps can usually take about 7nm of torque which is sufficient. There is no need to double up clamps. If however a clamp is stripped then a new one should be used.

[Killerwatt]

Are you using the right size of silicone bend?
The stock intercooler is 60mm iirc. If its a 63mm bend you will have issues. Also why do you upgraded pipes and stock intercooler?

[casperjjordaan]

I bought the car with the newer piping in. Have no idea why they upgraded the piping. The 90deg bend that comes out of the intercooler had a hole in it, so I had to replace the bend, but a OE 90deg bend from VW is R3 960 ex vat. I refuse to pay that. And yes, I took the intercooler with me when I bought the hose.

[Donavan]

on the plastic pipes of the cooler you can use Q-Bond to make a ridge around the pipe

[xXx]

Hair spray works as well.

[VGTI]

Can I ask a stupid question?

I am going to anyway...

Why run this setup? Are you running extreme boost? If you are then get a proper front mount...

But since you are probably not, why don't you just revert back to an OEM setup? Sure you probably don't have the original piping but get them from a scrappy...

I have never in 14 years had a boost pipe pop off and blah blah blah, the turbo on my car boost properly and I use it everyday...

Again if you plan to upgrade in the future get a front mount and clamp it on there with the force of a pregnant Taurotragus Oryx!!