[s-cars] How I repaired my turbo intake hose aka Frankenhose

[chris chambers]

I received several inquiries about how I repaired my hose in the middle
of nowhere. Because of this I took some pics to share, maybe it'll help
some one.

The pics are located here:
http://photobucket.com/albums/v48/chrisanjenn/Audi%20S4/franken%20hose/


This is a pic of the typical hose failing at the hoes clamp area of the
turbo.
http://img.photobucket.com/albums/v48/chrisanjenn/Audi%20S4/franken%20hose/Intakehoserepair001.jpg

This is a close up, you can see mine was not connected anymore,
actually I had 3/4 of an inch of rubber holding the two pieces
together.It's amazing but the car actually ran still!
http://img.photobucket.com/albums/v48/chrisanjenn/Audi%20S4/franken%20hose/Intakehoserepair002.jpg


First step is to cut off the area of hose that the clamp goes around,
for me this was easy because it was mostly seperated anyway!
http://img.photobucket.com/albums/v48/chrisanjenn/Audi%20S4/franken%20hose/Intakehoserepair003.jpg

Next go to your favorite muffler shop and have them make a 2" diam pipe
for you that is ~3" long, have them flare the ends in so it will slide
into your hose easily.
http://img.photobucket.com/albums/v48/chrisanjenn/Audi%20S4/franken%20hose/Intakehoserepair004.jpg

Slide the steel pipe into your hose, using a drill bit push it into the
"T" of the hose that is pointing straight up in this pic. Hold the
drill bit hard against the steel pipe and turn the pipe back and forth
scoring a line on it.
http://img.photobucket.com/albums/v48/chrisanjenn/Audi%20S4/franken%20hose/Intakehoserepair005.jpg

Now cut along that line, making a nice wide clean cut. Debur teh pipe
inside and out, you don't want any pieces of metal that could come free
and go into your turbo and engine! When you put the pipe back into the
hose this cut will allow that T to work. Without doing this you won't
have any boos! (please don't ask me how I found this out!:-) )
http://img.photobucket.com/albums/v48/chrisanjenn/Audi%20S4/franken%20hose/Intakehoserepair006.jpg

Now taking a nie sharp ravor blade cut a slit in your host as seen
here. This is to clearance for a hose clamp. I used a razor blade, this
knife is there to show the cut. As always be careful not to cut
yourelf!http://img.photobucket.com/albums/v48/chrisanjenn/Audi%20S4/franken%20hose/Intakehoserepair008.jpg

Now you will also need to visit your local Home Depot/Lowe's and get
one of these. It is a plumbing connector that steps from one size to
another. You will want 2" on one end and then match as close as you can
to the intake size of your turbo on the other. Because there is limited
space cut this down on each side so that its just big enough for the
hose clamps with some extra space. I removed ~ 3/4" from ach side of
mine. A few people wondered how this rubber would handle the heat, this
hose in this picture was in place for ~1200 miles before this picture
was taken The only distortion is because it was bigger than my turbo
intake so I squeenzed it down with the clamp.
http://img.photobucket.com/albums/v48/chrisanjenn/Audi%20S4/franken%20hose/Intakehoserepair007.jpg

Slide the rubber coupler over the steel pipe, place the clamps and
tighten.
http://img.photobucket.com/albums/v48/chrisanjenn/Audi%20S4/franken%20hose/Intakehoserepair009.jpg

Here is the final product, ready for duty!
http://img.photobucket.com/albums/v48/chrisanjenn/Audi%20S4/franken%20hose/Intakehoserepair010.jpg


Hope this helps...and I hope the pics come through ok!

Chris



		
_______________________________
Do you Yahoo!?
Declare Yourself - Register online to vote today!
http://vote.yahoo.com