Machine Workz Stage
The machinist who created the original downpipe, the VAF cone adaptor, and the intercooler top tank, also completed the rest of the car's piping requirements.
During the process a few things changed...
Dual Stage Intercooler
Since the first page was completed, I aquired a second Saab 900 intercooler. Getting all the machining requirement done at the same time was a good idea.
Drama unfolded upon finding out that not all Saab 900 intercoolers are created equal. The bar spacing and sizing between intercoolers were slightly different. Time and money pressed. The decision was made to use the denser core on the Hotside being fed by the Turbo, and the coarser, less restrictive core was placed feeding the intake. This mandated a pipe routing change as well as fabrication of a new top, center, and bottom tank. I am happy with the end result. I think this configuration will provide adequate cooling!
The Dual Stage intercooler is born!
The cores were joined in the center integrating the new hoodlatch support. Additional support in behind the intercooler insures that not all the weight is resting on the intercooler.
To your left you'll see the new powersteering cooler pipes and the frame modification to allow the 2.5" mandrel bent intercooler pipes access to the engine bay. The right side of the frame recieved a similar modification. This position allows the stock bumper to remain unmodified in keeping with the sleeper look.
Intake Piping
Beginning with the RX-7 Turbo VAF, a MX-6 reducer was used to connect the 3" outlet to the compressor feed pipe. The original restrictive plastic compressor feed pipe was replaced with this much smoother mandrel bent 2" pipe to match the intake of the compressor. The very restrictive flat pipe immediately after the turbo compressor was replaced with a 2.5" mandrel direct to the intercooler.(Very tight fit!)
Exiting the intercooler is a 2.5" mandrel back through to the engine bay. This is connected to the only original intake pipe leading to the throttle body. This intake system should flow!
T304L STAINLESS EXHAUST
The machinist continued his fine work to complete what he had started with the down pipe. The cat pipe flange was machined to maximize seal and flex with the graphite doughnut connection. 
The pipes are Italian T304L Stainless steel, originally spec'd for brewery piping, polished inside and out! Originally, I purchased Dynomax mandrels for this task but soon found that not all mandrels are created equal! The Italian piping keeps a continuous dimension throughout the bend. The same could not be said of the off-the-shelf Dynomax stuff. All stainless steel flange connections are TIG welded to the pipes using "everdure" alloy rods instead of stainless to minimize cracking at the welds that can occur at stainless stress points.
The pipes use all the "factory" hanger locations. The mandrel pipe continues back using these nice threaded connectors out to the DynOmax Ultraflo Stainless Steel muffler! Check out the hanger placement on the Muffler.
Exiting out this simple, effective no-rice tip.
Continue to: On the Road!....
