IC hoses keep popping off

[kjhansen]

I just finished up putting in the Ford Superduty Front Mount Intercooler and the hoses keep popping off. I have super clamps (bolt-down--$6.00 EACH!!!) instead of the screw-down kind, but no "ridge" on the tubing. I can run 20psi of boost on 91 octane with alcy injection with only 1.6 degree of retard on the 2-3 shift, so that's cool. But I do run into a traction problems in 2nd gear... get sideways a bit. But over 20psi of boost the hoses pop off. Any ideas?
BTW, it was a royal pain to install the FM. Not near as easy as it appears in all the web sites where people take a lot of pictures etc. But it's in. At only $150 (E-Bay) for the intercooler I guess I can't complain.
Keith

 

[Mease Performance]

hoses

make sure you have the proper size Tbolt clamps, they may be too small and bottoming out.

also take a pair of vise grips and "flare" the end of the pipe slightly in as many spots you can to keep hose on pipes, best way to do this would be to find someone with a bead roller and have them roll the ends of your tubing. if you send us the tubing we can do it for $5 and end.

hope this gets ya rollin

<KM>@MPE

 

[Mease Performance]

clamps too large, sorry

ttt

 

[strikeeagle]

Keith,

Sounds like you're already using t-bolt clamps? They'll give you the most clamping power.

Are the hoses, tubes, nozzles and clamps squeaky clean? If not, they can slip. Clean them with a mild solvent if need be.

Are the hoses long enough? Short hoses are prone to popping off. I have a whole box of "too short" hoses in the basement. I finally ended up buying some longer straight and reducing hoses. I have to slide the hoses onto the intercooler tubes, then back onto the throttle body, intercooler nozzles and turbo compressor they're so darn long, but they don't move around on me anymore.

One last thing. Are the hoses NOMEX reinforced silicone? These hoses don't grow and shorten under pressure like some lesser hoses do.

Good luck!!!

 

[kjhansen]

Good advice. The Tbolts are not too big or too small, but I need to put a lip on the pipes and probably get different hoses. These ones are too soft and probably too short too. I can put two clamps on longer hoses!
Thanks.
Keith

 

[BlackBeauty]

I had the same problem from turbo to i/c after I installed a TE-44. The original hose was 2", and barely reached from the turbo to the i/c. I had to buy a 3" long hose at $2 per inch, but worst of all, shipping cost more than the damn $6 hose! But the proper silicon hose was nowhere to be found locally, I checked everywhere.

 

[J Banning]

You can put a lip on the end of the pipes by going to a muffler shop and have them do it with their pipe expander (that's what I did). You just barely put the end of the pipe on the machine, then flare the end. Don't go to far or you won't be able to put the hoses on. Make sure you file/grind the edges before putting the hoses on or you'll risk cutting them.

Good luck, and make sure you post some of your comments on the install to the prior PSIC threads (for the use of future people trying to do it).

-Banning.

 

[jastrckl]

I used this ghetto $6 or so pvc pipe coupler, has a groove for hose clamp in it. The thing is like 1/4" thick rubber. Amazed me when I saw that I wasn't the first guy to do this, here's a site of a guy I met on irc (#turbobuick on chat.camaroz28.com) that has a similar setup to mine: link

I didn't do the turbo to IC in this pipe because I figured heat would be a problem. He says he had problems with his cracking in that area. The colder pipes further away from the turbo work great though for me (after the intercooler). They held up under 25+psi of boost so they work pretty well.

 

[buickfreak]

I just MIG WELD a small lip about 1 1/2 inch long around the edge at three different place on the pipes tips, no way it can pop off now with the bolted clamp stuck on the lip edged pipes. I bought some new hoses at an AEROQUIP store , they sell them by the lenght you want , 2 feet was enough for me . I Custom cut the hoses to what I needed and sprayed some dry silicone lubricant on the welded lip to slide the hose on . The problem was cure for ever.

 

[turbo buicks]

the rubber plumbing hose that jastrckl used may work on the post IC tubes but do NOT use it from turbo to IC! i blew one out at 13 psi after 10 mins of driving. probably my 3rd or 4th time into boost too.

 

[tom h]

Originally posted by turbo buicks
the rubber plumbing hose that jastrckl used may work on the post IC tubes but do NOT use it from turbo to IC! i blew one out at 13 psi after 10 mins of driving.

Yeah, those soft rubber "Fernco" fittings are intended for Drain-Waste-Vent (DWV) plumbing applications, where there is nearly zero pressure. I can't imagine those holding up reliably under heat and high pressures ...

 

[jastrckl]

They hold up under 25+psi of air pressure. heat is what kills them. that's why I didn't even bother trying one for the turbo to intercooler joint, -only- the ones after the intercooler, at each end of the up-pipe.