A parts list for plumbing in Saab 900 i/c

IronMonkeyL255 · Post by **IronMonkeyL255** » Fri May 14, 2004 10:05 pm

I just ran around today getting everything I need to install mine. I haven't seen all the info in one place, so I decided to post the part #s and what I paid for them.

I got everything in 3 places:

~Pep Boys~
- Molded Radiator hose.................................................14.99
(E)70664
- 18" Tail Pipe Extender (2" ID)..................................... 4.99
548623
- 1 3/4" ID -> 1 3/4" OD exhaust adapter...................... 2.49
548515

~Home Depot~
- 2" Rubber Flex Coupler................................................ 3.97

~Ace Hardware~
- 3/4" Galvanized Barb adapter..................................... 1.99
or
- 3/4" Pipe Nipple.......................................................... 0.59

~Total Cost~................................................................. 29.02 before taxes

~The Reason For My Choices~

-The radiator hose is for duplicating the post-turbo bend and to line it up with the inlet of the i/c (BAC 5.2 alerted me to this use).

-The large end of the exhaust adapter fits PERFECTLY inside the main tube and the small end fits perfectly inside the radiator hose.

-The tailpipe extender (will be cut down later) has an inside diameter of 2". One end is slightly flared to allow other tubing to be inserted and later welded. The larger end goes to the i/c inlet and the smaller end gets fit with the adapter.

-The flex coupler is about the same as a Samco-style hose that most of you end up using. It is rubber instead of silicon, so I am going to have to watch to make sure it doesn't melt. It is used to connect the main pipe (TP extender) to the i/c inlet.

-One of the Ace fittings will be welded to the TP extender for the diverter valve. I picked up one of each, so I will probably end up returning whichever one doesn't work. I am hoping to use the barb fitting, though.

~Other Pieces of Info.~

-If you wanted to cut costs even more, you could skip the rad. hose and just cannibalize the stock elbow. I wanted to retain that piece, so I went with the hose.

-I didn't include the i/c in the price list, as you can usually find them for various prices around town or on ebay. I recieved mine when I purchased the car (thanks Opie), so mine was free.

-I tried fitting the rad. hose onto the TP extender, but it wouldn't fit. I ended up going through all the exhaust adapters they had on the rack until I found one that fit PERFECTLY. I plan on having that welded on as well.

Lemme know if this helps you in any way. I gathered the various pieces of info from around the boards (vrg3 was quite useful in this) and asking some of my other (non-Subaru) turbo friends.

IronMonkeyL255 · Post by **IronMonkeyL255** » Fri May 14, 2004 10:53 pm

Oh, yeah.

Once I get the stuff welded up, I will post up a few pics of the install.

I will probably paint the pipe flat black (keep it fast, keep it flat black) before installation.

BAC5.2 · Post by **BAC5.2** » Sat May 15, 2004 1:41 am

I ditched the Radiator hose in favor of a modular set up.

The pipe I had made, which was a 2" OD pipe, won't fit into the radiator hose, and a coupling (1.5" flex-coupling) won't clamp onto the radiator hose without crushing it.

SO, I got a 2" 90 degree elbow a set of 2" reducers so the 1.5" mild-steel pipe I had welded would fit into the elbow, and so the elbow would fit onto the turbo outlet. Then a 2" to 1.5" reducer to snug the welded pipe to the IC inlet.

I haven't installed it yet (I'll do it tomorrow probably), but it looks legit and should work properly.

Lol, stealin my quote about Flat Black are ya?

Total cost post tax was $35.67 including the welded pipe. $50 for the Intercooler, puts me at $85.67. Can't beat that deal with a stick.

IronMonkeyL255 · Post by **IronMonkeyL255** » Sat May 15, 2004 1:56 am

I noticed that problem too, which is why I got the adapter. It fits snugly into the pipe, and the radiator hose fits onto the end.

Next time you're at Pep Boys, give my idea a try. You'll see why I did it that way.

I may get some pics to demonstrate.....

I'm just borrowing the quote because I think it's cool. If you want it back......

BAC5.2 · Post by **BAC5.2** » Sat May 15, 2004 2:06 am

Nah, you can use it. I got it off a buddy of mine anyways.

I'll definately see about your idea. What is the adapter like? With my method, there is no passage that's narrower than the turbo outlet. Plus, rubber around every fitting to ensure a nice and snug fit. I don't THINK I'll have to worry about meltage. I'll see about your idea and see how it works though. I'd love to see some pictures.

IronMonkeyL255 · Post by **IronMonkeyL255** » Sat May 15, 2004 4:32 am

That fitting is the smallest part of the plumbing. It's about 1 3/4" OD at the smallest, with 2" ID or larger the rest of the way.

I'm not sure how large the rad. hose is, but I think it's right at 1 3/4" ID. The adapter fits PERFECTLY into the hose.

I was debating using a pipe expander to enlarge it a little to make everything near perfect before welding, though.

Also, other than the welds, every piece has a flexible coupling between it.

Oh, yeah. The adapter was just a short (3" or 3.5") piece of pipe that was flared on one side.

IronMonkeyL255 · Post by **IronMonkeyL255** » Thu May 27, 2004 10:33 pm

The galvanized barb adapter is exactly the right size for the DV tubing.

It fits in there nice and snug. With a hose clamp, that should be as tight as the factory seal, if not tighter.

vrg3 · Post by **vrg3** » Fri May 28, 2004 2:58 pm

The stock DV tubing is 19mm, which is five hundredths of a millimeter smaller than 3/4", so 3/4" is good.

It's just that it can be hard to find a 3/4" barb adapter. A 1/2" pipe nipple is a bit smaller than 19mm in diameter, but it might work if you clamp down hard around the threads.

IronMonkeyL255 · Post by **IronMonkeyL255** » Fri May 28, 2004 5:37 pm

That's why I mentioned both in my list.

I got lucky when I was looking around at Ace hardware. They have almost everything one would ever need.

vrg3 · Post by **vrg3** » Fri May 28, 2004 6:36 pm

That's cool. I guess they're one of the places that still takes pride in stocking a complete inventory and considers that a good product, instead of only trying to please the richest 70%.

free5ty1e · Post by **free5ty1e** » Mon May 31, 2004 11:03 pm

Agreed... Home Depot has zero selection when it comes to fittings and tubing. Every time I've gone there for one of my DIY projects I'm dissappointed. Better off with an Ace Hardware - never been dissappointed there.

So do we have consensus on the final parts list to install the Saab 900 IC? I'm lookin to get me one on ebay shortly, no junkyards around here seem to have any Saabs. Craploads of Saturns, which doesnt help me anymore... just my luck

IronMonkeyL255 · Post by **IronMonkeyL255** » Tue Jun 01, 2004 4:07 am

I haven't fit everything together yet, but I'm pretty sure that's all I'll need.

I may pick up a slightly smaller i/c > TB connector, b/c the one I have is a bit too big to seal well.

BAC5.2 · Post by **BAC5.2** » Tue Jun 01, 2004 4:22 am

Mine still isn't all together either.

I tried it with my elbow method, but it didn't work. The elbow hit the turbo inlet. Poop.

So I'll be using the radiator hose, the pipe reducer, and the various plumbing adapters to get it all to work.

Monkey - Go to a performance shop and get a 2.75" SAMCO style hose. Go to home-depot and get a 2" pipe coupler (these are calibrated for 2" ID PCV pipes, which push the actual ID to right around 2.5"). Cut the 2" coupler right around one of the fittings. Place it inside the 2.75" SAMCO style hose. Clamp it down. You basically made your own reducer. The 2.75" SAMCO style hose fits perfectly around the Throttle-Body.

IronMonkeyL255 · Post by **IronMonkeyL255** » Tue Jun 01, 2004 9:10 pm

Unfortunately, there aren't really any performance shops around here......

The few that are have NOTHING. Seriously, I walked into one of them and there was a body kit for an integra. That was ALL they had in........

Hmm..... so 2.75" fits just right.........

BAC5.2 · Post by **BAC5.2** » Tue Jun 01, 2004 11:10 pm

Lucky integra ricer.

Yea, 2.75 seems to fit perfectly on my car.

free5ty1e · Post by **free5ty1e** » Wed Jun 02, 2004 1:15 pm

I love how somehow body kit = performance upgrade. Add some kanji stickers for another 50 hp. Don't forget the VTEC emblem upgrade

IronMonkeyL255 · Post by **IronMonkeyL255** » Wed Jun 02, 2004 3:50 pm

And altezzas........

IronMonkeyL255 · Post by **IronMonkeyL255** » Wed Jun 16, 2004 11:51 pm

Update!

I was goofing around under my hood to see how everything would fit.

Now that I have moved the igniter, all I have to do is unscrew the beeper for my alarm (gonna have to move it when I install the i/c.....) and I could position it how it needed to go.

It's a bit bigger than I had anticipated, but it fits. I bent the bracket for the cruise control thingie so the nubs on the i/c wouldn't hit it. The outlet for the i/c goes very slightly into the TB (about 1/8", if that), but not far enough to interrupt the butterfly (i'll have to check to make sure.).

I was surprised to see that the smaller bend in the rad. hose worked almost perfectly. I had cut it off expecting to use the large 90 degree bend, but the smaller one works great. I am going to cut a little more off of it so there is more room for the main pipe between the i/c and post-turbo bend (I'm making it about 6.25" long).

Now I can measure everything and get it cut so my friend can weld together my pipe.

free5ty1e · Post by **free5ty1e** » Thu Jun 17, 2004 7:53 pm

I just won a 1989 Saab 900 turbo SPG plastic-end intercooler off ebay, should be here in a week or so. If you're done with your install by then could you post a final list of parts to get to do this? Maybe even some pictures? I've got webspace to host em if thats a problem - just email them to me. Every little bit helps. and I want to make sure I've got everything lined up when I finally get a chance to install it.

IronMonkeyL255 · Post by **IronMonkeyL255** » Thu Jun 17, 2004 10:27 pm

What I have listed should be it.

I should be doing this once I get the pipe welded up.

I'll take pics of the install.

free5ty1e · Post by **free5ty1e** » Fri Jun 18, 2004 1:17 am

sweet... thanks

Ought to go smoothly with this board's help. I love this place!

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A parts list for plumbing in Saab 900 i/c

A parts list for plumbing in Saab 900 i/c