Aluminium pipes & bends
Aluminium pipes are used in many types of vehicle projects where a lightweight, strong, and practical solution is needed for building pipe systems. They are often used for intake systems, charge pipes, intercooler pipes, air routing, and other installations where low weight, good durability, and easy adaptation are important qualities. In tuning, motorsport, and custom builds, aluminium pipes are a popular choice because they offer great flexibility when building systems that need to match the specific vehicle and setup.
One of the advantages of aluminium pipes is that they combine low weight with good strength and a clean finish. They are easier to work with than many heavier materials and are therefore often used in solutions where a functional and professional installation is desired. Aluminium pipes are often seen in turbo setups, where they are used as charge pipes between the turbo, intercooler, and intake, but they can also be used in other air and pipe systems where stable and durable connections are needed.
When choosing aluminium pipes, it is important to look at diameter, wall thickness, length, bends, and how the pipes need to be adapted to the rest of the system. It makes a big difference whether the pipes are intended for pressure systems, air routing, or other technical installations, and it is important to choose a solution that matches the load, space available, and the desired build. Together with the right joiners, hoses, and clamps, aluminium pipes can help create a reliable and efficient solution.
Aluminium pipes are used for repairs, upgrades, and complete construction of new systems where standard solutions are not always enough. Whether you are building for a street car, race car, or a more specialized motorsport project, aluminium pipes are a relevant solution when you want low weight, good durability, and flexibility in your setup.
All pipe dimensions are outer dimensions (OD)!
Frequently asked questions about aluminium pipes (click to open)
Which diameters are most popular for intercooler/intake?
2.5" (≈63 mm) is the most common in universal kits for turbo petrol/diesel applications. 3" (≈76 mm) is often chosen for higher flow/power levels or to reduce pressure drop on the cold side. Smaller cars/compact setups may use 51 mm/57 mm.
Are the dimensions shown on the site outer diameter (OD) or inner diameter (ID)?
All listed pipe dimensions are outer dimensions (OD). Therefore, choose silicone/HD/Wiggins couplings according to the pipe’s outer diameter.
What is the typical wall thickness of aluminium pipes?
Standard straight pipes/bends are typically around 1.8–2.0 mm. Cast bends may differ and have thicker walls (smaller ID at the same nominal size).
Which lengths and leg lengths are available?
Straight pipes are often 600 mm. A 90° bend in 2.5" typically has a leg length of around 190 mm. Other sizes may vary.
Do cast 90° bends affect flow?
Yes, they provide compact solutions but often have a tighter radius and a less effective cross-section (smaller ID). Where space allows, long-radius bends/mandrel bends provide lower pressure drop.
Which couplings should I choose – silicone, T-bolt, HD or Wiggins?
Silicone + T-bolt: Standard solution for most setups. Combine with bead-rolled pipe ends for secure retention.
HD clamps: Quick disconnection, high sealing, and tolerance for movement/misalignment. Used for high boost/track use, but require welded ferrules.
Wiggins: Motorsport/aviation quick release for low/medium pressure; chosen for quick service and weight/finish.
How do I prevent hoses from blowing off under boost?
Bead-roll the pipe ends, use correctly sized T-bolt clamps, and place the clamp behind the bead (not on top of it). Degrease and deburr cut surfaces before installation.
Can I weld aluminium pipes myself – and what is best (TIG/MIG)?
It requires that you have an AC TIG welder. Remember thorough cleaning of oxide, correct fitment, and proper heat input.
Can aluminium pipes be used for exhaust?
No. Aluminium loses significant strength around 200–250 °C and is unsuitable for the hot side of exhaust systems. Use stainless steel or Inconel for exhaust/downpipe.
Are aluminium pipes suitable for coolant/intake air?
Yes. For coolant, corrosion resistance is good, and for intake air/intercooler, low weight, easy fabrication, and thermal conductivity are advantages.
What about petrol/E10/E85?
For petrol/E10, aluminium is generally unproblematic with correct design and maintenance. With higher ethanol content (E85), aluminium can corrode faster under certain conditions – consider anodizing/surface treatment, suitable fittings/liner, or stainless steel in the fuel section for long service life.
Which finish is recommended (polished, powder coated, anodized)?
Polished looks good, but requires maintenance. Powder coating is mainly cosmetic. Anodizing (preferably hardcoat/Type III) provides significantly better wear/corrosion resistance – popular as black hard-anodized for track use.
