I just got done installing my HKS Super SQV in my car with the stock cold side pipe, this can also be done with any aftermarket blow off valve as long as you have a weld-on flange.
Materials needed:
BOV
BOV flange
1/8" NPT nipple with 1/4" nipple
5" of 2" pipe
2-2 1/4" hose clamps (t-bolt clamps are much better)
about 2 hours of fabrication and 19 hours to put bov in the flange
Tools needed:
Welding machine
11/32 drill bit
25/32 drill bit
1/8" NPT pipe tap
Plasma Cutter
*Note: all of these tools aren't necessary, they just make the job easier*
You want to start off by removing your stock airbox if its still in there. Then start taking off the stock cold side pipe that connects to the throttle body and intercooler by loosening the hose clamps with a 5/16" or 8mm socket or a flat screwdriver. The two plastic locking rings holding the plastic pipe to the rubbers need to be taken off, I just cut them at an angle with a hack-saw. Be very careful not to cut into the rubber. Once they are off take off the hoses and get ready to fabricate!
Cut a piece of your pipe to the length of the stock plastic piece (about 5 inches but dont quote me).
Drill an 11/32" hole in the pipe making sure you leave room for the hose to fit on.
Tap the hole you just drilled with an 1/8" NPT tap (make sure you dont run the tap in all the way since they are tapered and the nipple wont fit right)
Now drill a 25/32" hole beside the hole you just drilled and tapped (make sure you start with a really small drill and work your way up to 25/32")
File the 25/32: hole until the temp sensor grommet fits well. Take the piece out to the car and make sure the temp sensor fits in very snugly, emphasis on the snugly. This way you can run lots of boost without having to buy a screw-in sensor.
Next you need to cut the hole out for the BOV. Personally, I put the flange on the opposite side of the pipe than the other stuff so it doesn't get too cluttered. I used a plasma cutter to do this but you can use a drill if you feel the need or a torch or whatever you can to make this hole.
Then you will need to weld your flange to the pipe over the hole you just made. Make sure it is a good weld with no holes. You can gas weld, arc weld, mig weld, or like I did Tig weld the flange to the pipe. If you think there is a hole, save yourself the trouble and go ahead and put some more weld on it.
Mount the BOV in the flange, I know the HKS is a pain in the @$$ but just take your time and save yourself the trouble and get a really good pair of snap-ring pliers, they will cut about 30 minutes off of the BOV installation.....Trust me, or just ask anyone else that has an HKS BOV.
Now all you need to do is put the hoses on the pipe and throw it in the car! Make sure you leave the hose clamps loose so you can position everything easier in the car while bolting it up. Make sure that while you are in there zip-tie ALL vacuum lines and hose clamp the big ones. I tightened the clamps up with a socket just to make sure they dont leak, but furthermore T-bolt clamps are always better.
Now heres some pics of the parts, process, and finished product!
Hks bov flange
1/8" NPT to 1/4" nipple
Temp sensor grommet (just rob it out of the stock pipe or buy one from autozone)
The hole for the nipple (already tapped)
The hole for the temp sensor & grommet
The whole piece with both holes
Nipple and temp sensor grommet in the pipe beside stock plastic piece
Heres a pic of the welding process
Heres the flange welded to the pipe (you can see the little "tits" I welded on to help prevent the hoses from popping off, since I dont have a bead roller)
Heres the bov in its new flange and pipe with the nipple for the red vac line and the temp sensor grommet
This is the completed cold side pipe with the stock rubber hoses
And finally the finished pipe in the car with everything hooked up! Hip hip...horray!!!!
Now enjoy your new home-made bov pipe and the awesome sound!
If you can't weld, there is another cheap option. Go to ebay and buy an adapter flange and pipe thats already put together, then just do the drilling and tapping part of this, and you will still come out at about a $150 savings on a hard pipe. Here's an example of the flanged pipe I am speaking of:
How-To: Fabricate Stock Cold Side Pipe for Aftermarket BOV
lol, i did this same exact thing from the get go. nice how-to tho.
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