Hello all I was hoping to get some helpful tips from those who have more experience than myself. I will preface my questions by saying that this work is for a Nissan 240sx but I love this forum and the answers will apply to Hondas as well so I figured I would ask here.

Here is a list of tools I have:
SawsAll
4.5" Angle Grinder
Hack saw with miter box

I am looking for tips on how to cut and finish piping for the intercooler and the upper downpipe (really all piping in general) in an average garage with limited tools. I have made some cuts in the aluminum intercooler piping using a hack saw and a miter box but that still turned out like crap. When it comes to doing the 304L for the 3" exhaust stuff I have no desire to hack saw it up. So my question is wheather a recriprocating saw can be used effectively to do straight piping cuts or if it is worth it to buy a chop saw and a disc sander to cut and finish piping and just sell it when I am all done.

How about techniques, the downpipe I am building goes from the turbo exit to a flange on a lower downpipe and I plan on rerouting the wastegate dump back into the downpipe just before the lower flange.

Pics:



Car specs:
1997 240SX
Fully built KA24DE
Arias pistons, K1 Tech rods, Calico bearings, cometic HG, etc.
PeakBoost mani, Garett T3/T04E 57Trim, and tons more.

 

Based on the information that you provided here is how i would attack the piping job:

a) Turbo Flange to Downpipe flange. If you plan on using 304L, just take it to a fabshop to have them do the whole thing. I realize that you would want to do it yourself, but considering the materials and the tools you have available it wouldnt really be worth it. If you had a welder and planned on using mild steel by all means go at it.

b) Compressor outlet to charge pipe: Get an extended peice of silicon coupler and just bridge the gap with it. That or purchase a small aluminum fill piece and two couplers, your choice.

c) Connecting the charge pipe to the upper charge pipe: again try to use the extended silicone couplers to finish the plumbing.

Without a access to a larger array of tools or a welder i would reccomend against trying to hard pipe these connections... my .02

 

Woops I forgot to mention that I have a small Hobart MIG welder at my disposal, I know that that does nothing for my intercooler piping but I was planning on tacking all the exhaust stuff together then bringing it over to a friends house and having him attack it with his super skills and his Syncrowave TIG.

Still think I should ditch the plans for doing it myself? For the compressor outlet pipe I plan on just having both sides of that elbow extended an inch or so to make it fit perfect, then for that upper cold pipe I just need to cut a 90* bend a bit shorter and have it welded to the upper pipe with the masking tape on it. then I can just connect it to the lower cold pipe with a straight connector.

 

I'd say buy the chop saw and keep it. I use mine all the time for stuff around the house as well as projects. I got a decent one during an aftermarket christmas sale for $60.