I saw a post kind of like this on a VW forum, decided it would be cool to start over here as well....

I'm currently trying to get the most out of my 99 v70xc, and while doing some research, I found IPD's Reverse intercooler piping kit.... for almost $400. They claim it reduces IATs by 53* just by reversing the flow through the intercooler. (heat rises)

I decided I could make one cheaper on my own, so I set off to the hardware store.

I picked up about 2 feet of 2" PVC, a couple 45* and a 90* coupler. I then got some fiberglass tape and some resin. I fitted the PVC up to run from the turbo outlet to the top of the intercooler, wrapped the PVC in plastic, and wrapped it in the fiberglass. After it set, I cut the fiberglass off of the PVC like a cast. I sanded the imperfections from the inside, and coated it with another layer of resin.

Tomorrow, i will paint the inside of the tube, and reattach the two halves together by glassing another couple layers around the outside. I'll be starting the process for the lower tube tomorrow as well.

All in all, I'll be able to do the intercooler reversal piping for under $100, and the fiberglass will dissipate heat much more efficiently than the PDI Stainless tubing.

After I complete the reversal tubing, I'll be working on an inlet tube for a cold air intake. I'll be relocating the battery to where the stock airbox was, and directing cold air straight into a fabbed air box right behind the left headlamp.

Pictures coming soon, feel free to post any cool mods you have done to get the most out of your Volvo. Be sure to include what you did, how you did it, why you did it, and the overall cost!

 

Have you finished your project? I'm curious how it turned out and if there was/is a noticeable performance difference. Any pictures?