Silicone hose is nice, but it is often hard to come by. I live near Belair Composites, which custom fabricates silicone hoses so I am lucky. I used to buy misc. pieces from their overstock bins for a fraction of the true value, but now they are trying to achieve ISO9000 certification and everything has to be meticulously accounted for. A $2 elbow now costs me $14.
The foreman at Belair taught me that you can weld two pieces of silicone hose fabric together by baking them at 300 degrees F for 45 minutes. I needed an 1 7/8" 45 degree elbow, but could only get a 45 in 2". I just wrapped my pipe with one layer of fabric, slipped the 2" elbow on and 45 minutes later it was a picture-perfect laminated 1 7/8" elbow (of sorts)
When I have needed a special piece, I have just used good quality radiator hose with no problems at all.
KY-Jelly works great for hoses that are a wee bit too tight. When it dries it is kind of adhesive. I used to use dish soap for tight fitting situations, but it always remains slick and is more prone to hoses coming undone at the wrong time
Silicone sealer and fiberglass cloth work wonders in difficult custom fabricating situations.
Never use ABS drain pipe or its fittings in plumbing an intercooler. It will work great until your first long hill on a hot day then it will collapse.
Bill Robinson
92 USA Legacy Turbo
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Silicone Hose versus Radiator Hose
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