homemade ic thanks/clarification

[Sachelle Babbar <sbabbar@iris.nyit.edu>]

I would like to thank the list for its support (no flames, yet!) on the
homemade ic idea. I figured that I'd be met with an incredible amount of
resistance based on the fact that i tend to think Home Depot-ish instead
of IA, TAP, etc. when an idea on a mod comes to mind. My wastegate
controller cost me only a few dollars and gives me 2.0 bar, my ic to tb
hose cost like 8 bucks, many other things.

BTW, I gave out bad info a few weeks ago, I tested my o2 sensor at 2 bar
and thought that the reading was indicating slightly lean. I was corrected
and found that it's on par with a good mixture.

The idea came to mind because I feel that my ic is the weak intake link,
may be leaking from a damaged core tube, simply an inferior design. Don't
get me wrong; it does the job fairly well, but it can be much, much
better. I guess the design team was one floor above team door handle's
basement design studio in Ingolstadt.

I have priced some items and more ideas have come along. Price may be a
little higher than I quoted by 20-30 dollars, but still cheaper than the
junkyard replacement ($175) and what Gary lewis got his 3b 20v ic for
($216) at the dealer.

Turbulators: I'm under the impression that turbulators are internal flow
swirl devices? If they are, that's not what I'm gonna use. I'll be using
external finning. Hopefully, I can get copper (as flashing) to solder on
my own. The final assembly will be modular? I'll assemble the core fully
to its end caps and those end caps will fit inside the end pipes on the
left and right. Everything will be soldered together, or as the idea comes
along with need, spot arc welds. I've experimented with this before on
thin copper tubing and should pose no problems to just tack things in
place and fill with solder.

Paint: I'll take my chances with the copper oxidation over the heat
insulating properties of paint.

Upgrade provisions/ports: I've already mentioned there will be a bypass
valve and vacuum/pressure testing ports. I neglected that there most
likely will be a port for a future sixth injector for fuel or water, but
have not seen the need for it in my applications. Would be cool to add
one. 

The best test is to see what the outlet temps are. I hope someone can test
their ic outlet temp and maybe someone can volunteer theirs for a day or
two? If I find out what the sensor fitting size is early on, I can design
a port for it.

In addition, the vacuum ports will double to allow carb cleaner spray to
be injected while the engine is running.

Water injection: If all remember, about 2 years ago I made a water spray
system for the ic core. Consisted of washer bottle mounted above oil
cooler, audi check valves, and a hair spray nozzle as the injector head.
Worked allright in the summer, but it's value to me was nil. Helped in
transition from off boost, high heat cruise to on boost. Was activated by
engine boost or by a dash button that activated the washer motor.

Anyway, I'm very happy with the list response and actually may get started
today. Later.

****************************************************************************
*Steve                                             Sachelle Babbar
*'87  5000CS Turbo 5spd 1.3-2.0 bar             <SBABBAR@IRIS.NYIT.EDU>
*Cockpit adjustable wastegate, AudiSport badge
*
*Disclaimer:"Any information contained herein is based purely on my own
*personal experience and may not necessarily reflect yours. Use caution as
*your results may vary from mine."
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