VMP '11-'17 Coyote Roush/Whipple replacement 3/4" aluminum fitting and tube kit

Zinc03Cobra

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Morning All,

If you're like me with an older blower like 2.3 Whipple/Roush/TVS/VMP or similar type, you may have to check on your steel transfer tubes to the intercooler. I recently noticed my car felt "not as fast" and it was discovered that my inlet/outlet tubes were completed clogged with rust and corrosion. No coolant flowing meant extra heat, and that extra heat caused a mild surge around 3-4k RPMS at WOT. The car went nowhere fast. The coolant pump stopped working too, but is back up and running.

Thankfully I saw that VMP had improved upon this Ford design and I had these parts overnighted from Florida to California. This next part will sound unorthodox, but I used CLR in the coolant system to break up any remaining corrosion in an all aluminum system. After a weeks worth of flushing and purging the system, we're back to clean / clear fluid. She runs great again.

Pics attached of how bad it was.

Big thanks to Shaun @ AED for helping me figure this out. Thanks for reading.

YouTube Link to VMPs video on this.

Parts that I used.
 

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Stangra

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I installed a Roush just over 2 years ago. I just pulled these tubes because I upgraded the intercooler system to 1-1/4" plumbing and components and was surprised to find the beginning of some corrosion forming in there already, Especially in the lower fitting.

I also modified VMP's 1" fittings from a hose barb end to -20AN fittings

20211118_192108_HDR_(1).jpg
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Stangra

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I started by pressing out the 90° barbed tube from the base and discarding.
I made a polished stainless bolt flange, but can save and reuse the original too.
20211103_093624_(1).jpg

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Then I separated the base into 2 parts so I could run a drill & NPT tap through the front half of the fitting without damaging the back half
20211118_172150_HDR_(1).jpg

Tapped threads and chamferred the mating surfaces at the edge for welding back together
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Cut off threads from new 45° fitting to match the depth of my tapped hole + thickness of the bolt flange.
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Welded together and turned on a lathe for a nice finish
20211118_191552_HDR_(1).jpg


Threaded the 45° fitting through the bolt flange and into the new fitting base. Ample thread sealant since there aren't many tapered threads to insure a pressure tight seal. O-ring seal functions as before modification, fitting can be swiveled in bolt flange before tightening (not just anywhere though, clearance for bolt heads is tight!)
20211118_192108_HDR_(1).jpg
 
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