Plumback Hose connection Difficulty....please help!
 

As some of you may now i recently went about installing a 01-06 giant TMIC in my gc8. Most of the installation required some sought of modification to parts etc.

Now the final bit is causing the most problems. THis is the connection of the plumback hose from the BOV to the engine. I know the easy solution is to get a full atmopheric, but not really to keen in going down this path as i dont want to be hasseled by the boys in blue and if i am will have to sought this problem out anyways...

so...my problem is that with this cooler i had to source a 01-06 stock BOV, which i did (pic below).
[URL=http://imageshack.us][IMG]http://img169.imageshack.us/img169/1931/37033299lg1.jpg[/IMG][/URL]

Th is very little room between the BOV outlet and the engine outlet to manouvere a hose without Kinking it. I have managed to connect a hose but it was kinked to the max and the car woul not run smooth, it ran really quite badly...This is the room more or less i have to work with...

[URL=http://imageshack.us][IMG]http://img261.imageshack.us/img261/9780/49283908nw0.jpg[/IMG][/URL]

Its is quite tight to demonstrate how tight....this pic shows just how tight!
[URL=http://imageshack.us][IMG]http://img410.imageshack.us/img410/6600/4tightqe5.jpg[/IMG][/URL]

Me and my team (dad) have thought hard about how to do it and have thought that maybe the best way is with some 90 degree steel bend to help create the desired shape with the hose. The shape of the hose NEEDS to be something along the line of...

[URL=http://imageshack.us][IMG]http://img410.imageshack.us/img410/6646/bendwm6.jpg[/IMG][/URL]

1...represents the start of the Hose. the BOV.
2...Is where we plan a 90 degree bend, with one end pointing at the BOV and the other in the direction of the other connection.
The hose will need to travel under the TMIC as it is only space with enough room.
3...represents an area where there is some soom and it is here that with some more 90 degree bends i plan on doing the 180 degree turn with the hose so it faces the other connection and then hopefully fingers crossed, simply connect to number 4.
4...represents the end...The engine connection bit.

I have spoken to some guys at PIRTEK, they sent me somewhere else...not much help :(.
Had a mate of Dads from ENZED come past today he said he couldnt help.

So yeah once i source these 90 degree elbows i am i need of, will give it another crack....

[SIZE=6][B]Can anyone reccomend me an alternative method for connecting the hose...i DONT want to go Atmo unless i absolutely have to!!!

Open to all suggestions guys...[/B][/SIZE]


Thanks John!!!

BTW: This is the cooler in the GC8 engine bay....big MOFO!!
[URL=http://imageshack.us][IMG]http://img261.imageshack.us/img261/9030/enginelg1.jpg[/IMG][/URL]

thanks guys

Now you know why i just gave up and went an atmo . . .

LOL

hahahaha yeh...only reason i am keen on finding a way is to stay out of trouble with the po po's....to get over the pits would need to sort this mess out anyways....aaarghhh so damn frustrating...havent event driven the car to feel the diff....sucks!!!!

go to bunnings and get some 25mm or whatever size 90 degree retic bit and some hose from HOSECO (or anything else), couldnt be that hard could it?

[QUOTE=mitcho]go to bunnings and get some 25mm or whatever size 90 degree retic bit and some hose from HOSECO (or anything else), couldnt be that hard could it?[/QUOTE]

lol

I wouldn't have thought it would have been *too* much of an issue if that BOV return hose was slightly kinked - It only gets used when you change gears.

Even if there is a bit of a kink, I would have thought the suction of the turbo would have been enough to get thr air through it, even if it is a bit tight.

Not too sure why it'd idle badly though? As that pipe is not even in use when idling.

Edit:

I guess when it opens, more air may be feeling the pipe, and actually causing issues with the BOV closing/opening? Even if this was the case .. Would have thought it would cause a bit of flutter .. Not enough to cause the engine to perform badly?

IIRC the hose ID for that BOV return is 19mm right? Go to bunnings and get a 19mm reticulation hose to hose connector. and cut off the end barbs leaving only about 15mm of at each end. Get a piece of 19mm heater hose and extend the BOV return hose. You will need to use some worm drive clamps to ensure no leaks. That is all I can think of ATM.

Otherwise your going to have to remove that hose completely and replace it with a new extended length hose.

This might be worth a try.

A length of the correct size and length heater hose.

Insert a softish type spring inside the hose to help the formed bends not to collapse when you route it through.
Or may be better have the spring on the out side[not to restrict flow] covered in a braided sheath for a cosmetic appearance.

Nails

Thanks Paul will give it a shot ;) ;)