[s-cars] DIY FMIC - Almost done, hit a small snag...

[Lewis, Gary M]

Sheads,
I have the DIY FMIC nearly done (total costs now are ~$550), but I need to roll a bead on the ends of the aluminum tubing. The options I know of are:

1. Have it done locally at a machine shop ($100).  I'm leaning this way.  Technically great but a little pricey.

2. Buy my own machine ($400).  Charge everyone who will go after me like $40 to roll a bead on their pipes to recoup the costs.  http://www.vansantent.com/bead_tool.htm  This is technically good but pricey.

3. Do it by hand with a press.  Free but scary.

4. Use an aluminum epoxy ($10).  I have heard of some racers doing this, and apparently it works, but I sweat when a piece of the epoxy flies off and goes into my motor.  Scarier than #3.

5. Your super cheap and super brilliant idea here.

The sooner I get an answer to this problem the sooner I will post up pics and a parts list.

Thanks,
Gary Lewis

1995.5 S6 Avant, Green/Ecru, RS2 MAF, RS2 Exhaust Manifold, RS2 Injectors, Custom Turbo (K26 Turbine, Factory K26 Cold side (Audi Works '999' P/N) with 50mm intake and custom Innovative Turbo compressor wheel), TurboXS Type 25 Bypass Valve, Bilsteins, Eibachs, Big Reds, Spec II Clutch.