I had started a thread about a mysterious hiss that sounded like it was coming from the turbo but turned out to be the inter-cooler pipe (front right) split but thanks to the Algerian Hacker wiping out 3 weeks of Vectra-C.com that thread has bit the dust so I'm resurrecting this thread the best I can with my cheap repair solution to my split pipe.
So here is my split pipe
and here bodge repair if duck tape whilst I waited for the silicone pipe and 90 degree aluminum bend to arrive in the post.
I ordered 1 meter (smallest length they do) from ebay of 51mm (2") Blue silcone hose http://cgi.ebay.co.uk/51mm-2-Silicon...es_CarParts_SM
and a 51mm (2") beaded edge 90 degree bedn Aluminium pipe. The leg length of the aluminum pipe was 68mm (smallest I could find) which was still a little bit to big so I had to cut off the beaded edges for a better fit. If I was doing this again I would have ordered the longer leg length which was cheaper (£9.40 as apposed to £17!) and cut that down instead. Here is the link for the longer leg pipe: http://cgi.ebay.co.uk/ws/eBayISAPI.d...96&mfe=sidebar
The next thing was to cut the silicone hoses. The main pain in the arse was that the bottom part of the original pipe was wider at the bottom than the top so the silcone pipe had to stretch a bit and to make things a little trickier I had to cut a notch in the bottom of the pipe to fit it exactly as per the old one:
Then it was a case of putting in the metal pipe in and cutting the top hose. I bought brand new Jubilee clips and did them up nice and tight. Considering I had to get rid if the beaded edged of the pipe everything went on securely.
There is a bit to much of the top blue silicone hose after the 2nd jubilee clip and I will cut that down later but it was getting dark and about to **** down with rain. A job for another day.
As you can probably tell I did everything by eye rather than using a tape measure. If you are going to do this mod/repair perhaps measure things a bit more carefully than I did but in the end its all working! It was also alot cheaper than buying the silicone replacement off ebay for £63. This will cost about £30!