How To: Kill your turkey with stock pipes

[Mach 3.5 Turbo]

Aight, I got an Injen intake and was disgusted by the surging I heard from it. So I went out and bought an HKS SSQV BOV from someone on this forum. I didn't want to spend 1500 or even 300 dollars just to attach it to the car, so I set out to design a cheap flange. My brother really deserves a lot of the credit too. He's a pimp. For the undeducated, to kill your turkey (compressor surge) you will need to put an atmospheric BOV near the throttle body while leaving your stock BPV in place. See this thread for more information:

How To: Kill your turkeys

Anyway, you're gonna need some stuff first. I got everything I needed at Lowes for 16 bucks, including tools. I already had most of the tools though. Here's what you're gonna need:
1 1/4" insert plug (plasic piece, the flange itself basically)
Insert plug picture
2 sink stopper washers (1 1/4" ID)
Washer in bag
Washer pic
1 1/4" ID radiator hose, about 3 inches long
2 hose clamps for the outside of the radiator hose
1 1/4" hole saw (go cheap, they can be had for around 4 bucks)
1" hole saw
Hole saws picture
vacuum line and T-fitting (usually comes with your BOV)
Razor Knife
Epoxy (any thick type will work fine, I used JB Qwik)
And here's the kicker:
HKS flange adapter for a mitsubishi eclipe. See it in this picture. I don't know where to get one since my BOV came with it. Look around I'm sure they're out there.
Eclipse flange picture

Alright, get all this stuff (or eqivalents) before you start because you can't drive your car with a hole in the pipe. I'll post pictures of all the parts when I get a chance, keep checking this thread.

1st, drill out the center of the insert plug using the 1" hole saw, and file the whole smooth. Push one of the sink stopper gaskets down the insert plug until it hits the lip at the bottom.
Hole saw picture
Washer on plug

2nd, disconnect the IC pipe from the throttle body. There is a solenoid or something bolted onto the top of it. Unscrew this first. I just let it hang for now, I'll find a way to attach it late since my BOV is in the way now. Bend the pipe until you have it sitting on top of the battery. Heating the pipe with a hair dryer makes it a little easier to slide off.

3rd, drill a hole using the 1 1/4" hole saw in the IC pipe close enough to the entrance that you can get most of your hand to it. Closer the better. Make sure you know where you want it cuz once you've begun, you're done .

The next few steps must be done in just a few minutes, since most epoxies set up very fast. I didn't take any pictures during the process because I didn't want to screw this step up. Sorry.

Mix up your epoxy and slop it all over the rubber gasket on the insert plug. Put a lot on it, but keep it off the ridges. Push it through the hole you just drilled from the inside of the pipe (ridges out). Smear the epoxy all around the edge of the hole, basically make sure it's going to make a good seal. Wipe it off your finger then, or else you're screwed.

Now, you can either just hold the insert plug/gasket/epoxy tight against the inside edge of the pipe until it dries or you can hold up on the insert plug, push the radiator hose over the ridges until it's tight against the IC pipe and tighten a hose clamp around it. This'll just hold it until the inside epoxy can dry. Let it dry for a while, read the instructions on your epoxy for the drying time.

Now, take the radiator hose off the insert plug so that just the insert plug is sticking out of the IC pipe. Mix up the rest of your epoxy and smear it all around the edge of the inserft plug. Push the other sink stopper gasket down the insert plug and into the epoxy. Slide the radiator hose back over the ridges, push it tight, and clamp with a hose clamp. Let it dry. Imagine the pipe between the washers in this pic.
Both washers on plug

That's basically it. Now you have a 1 1/4" OD nipple sticking out of your IC pipe. This happens to be the OD on the eclipse HKS flange, so I just slid the BOV onto the radiator hose, tightened a hose clamp, and I was done. 100% turkey free, and no stalling at all. I can't even bog the engine. You can see it in the following pictures.
Close-up pic 1
Close-up pic 2
Engine bay pic

Check out these videos. They kinda suck and you can barely hear anything, but it's better than nothing. I used my still camera's video function so don't expect much. They're ZIP files, so you'll have to download them and then use Quicktime to play them. Listen close.

Crappy Video 1
Crappy Video 2

 

[mp5jeff]

if theres a thread with this info on it already why duplicate it? sorry i just got one of my threads deleted because of this i guess im still mad lol...

 

[tddelsol]

wont that cause stalling

 

[Mach 3.5 Turbo]

mp5jeff - This is more of a how-to thread.

tddelsol - No.

 

[tddelsol]

but your venting air already acounted for by the mas

 

[supman]

vids not working

 

[mp5jeff]

if you turn the idle up on the car, you won't staul if its vented to atmosphere(this was what my thread was about that got closed lol)funny thing is ive seen at least 4 people ask lately if it will cause stauling, oh well..

 

[Mach 3.5 Turbo]

If you read it, you'll see that I'm still using the stock BPV. If you use both, it doesn't stall or even bog. The BPV lets through what it needs and the rest is blown off. Works better than I would have thought honestly. Works great

 

[Mach 3.5 Turbo]

supman- the vids are zips, you have to download them, unzip them, and play them with quicktime. Sorry for all the crap, but it's the best I could get with my camera.

 

[Mach 3.5 Turbo]

mp5jeff- it won't stall anyway, but good idea. Yeah people don't read a post and then respond to it asking a question it already answered.

Read the thread before you post!!

 

[mp5jeff]

lol..

 

[2K3 MSP]

The other thread was for how to kill the turkey with hard pipes. It was definately hard to hear in the vids, but good job on getting this info out. (2thumbs)

 

[Mach 3.5 Turbo]

The videos do blow, but it's all I got right now. Trust me, it does sound good inside the car. Haven't let anyone else drive it to see how it sounds outside yet. I'll try and get some better videos or possibly just sound clips soon. Anyone in the Akron/Canton/Wooster area have a microphone setup? Or a digital camcorder?

 

[supman]

does it get the hks high pitch whistle?

 

[jflo]

can you explain more about the rubber gasket part where you shove it down the insert plug ? i'm kinda confused about that...also could u add that to the parts needed list ? all this info is great !

the bov is just being held up by the flange and hose right ? the flange is stuck deep into the hose and near the plug so it won't be bending over or anything right ?

 

[505zoom]

I can hear in your vid's that it sounds exactly the same as mine. You can actually hear the stock valve working as it should now. In addition to the normal HKS sound, you can hear the air recirculating back through the injen smoothly, just like the sound of air rushing through it under boost.

Great writeup Mach 3.5, I have edited my first post in the "kill your turkeys" thread to include a link to this info.

Again nice job man, I was hoping someone would take the idea and work it into the stock piping. Another turkey bites the dust.

 

[Mach 3.5 Turbo]

supman - yep it's got the high pitched whistle, you can barely hear it in the videos. My camera sucked, I'll get new ones as soon as I can.

jflo - the parts are listed as "sink stopper washers." The two I bought are already glued onto my car, so I'll try and get a picture of one at Lowes for you all. Yeah, the BOV is just held up by the hose. Inside the hose, it is actually sitting on the "insert plug." It doesn't really move around at all, just the slightest bit of flex to the whole thing. I plan on putting a little strip of metal between the BOV flange and that little plastic support sticking out of the top of the IC pipe, see what I mean in pic 2 at the bottom of the first post.

505zoom - Thanks man. I really owe you a lot of credit for trying this setup first. It takes a big pair to cut a hole in your aftermarket pipe not knowing how it'll turn out. My car sounds just like the clips of your car. How did you make them (what kind of camera/mic did you use)?

 

[Got_boost02]

that insert plug extends pretty far down into the intake tube doesnt it? what about a disruption in the air that is moving through there into the TB? do you think that it is enough to be concerned about? also, could you just alieviate that by cutting down the length of the insert tube? thanks!

 

[GI-]

Where did you run the vacuum tube to that is coming off the HKS BOV?

 

[505zoom]

505zoom - Thanks man. I really owe you a lot of credit for trying this setup first. It takes a big pair to cut a hole in your aftermarket pipe not knowing how it'll turn out. My car sounds just like the clips of your car. How did you make them (what kind of camera/mic did you use)?

(lol) I think it takes a much bigger pair to cut a hole in that giant stock pipe!

The vid's that I took were with a $30 mic that I got from Best Buy. I fastened the mic under the hood next to the battery, and ran the wire to the camera inside the car.