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80mm TIP Fitting instructions

Discussion in 'Badger 5' started by badger5, Jan 5, 2012.

  1. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jan 5, 2012]
    Below is a how to fit a B5 80mm TIP... if in doubt get a competant person to fit this, or alternatively we can fit them for £45+vat

    Firstly remove your original TIP from the car. If you cannot manage this, then please consider getting someone to help fit the new TIP.

    Once tip is removed clean off any oil which no doubt may have accumulated in the TIP and on the outside of the turbos intake. Brake cleaner or such is usefull for this.

    Prep the alloy billet adaptor with a light bead of silicon sealant on its internal diameter as pictured below.
    [​IMG]

    Have a 2mm allen key to hand to use to secure the grub screw into the turbo's slot. Ball ended are easiest to access. Also, add a small drop of loctite to them just prior to fitting the billet adaptor to both seal and secure it in .

    Slide the billet adaptor over the turbo, (it is usually best to dry test fit this before applying silicon to confirm it slides over nicely). Twist the billet adaptor as you slide it onto the turbo so as to smear the silicon evenly. Orientate the grub screws, so as you look at the turbo, its at 2 o'clock positions for easier access to nip up. Nip up to secure the billet adaptor to the turbo. It should be firm and not rotate.

    Wipe off any excess extruded sealant which has come into the bore. Ensure no silicon is allowed to touch the compressor blades when you wipe off this excess. Once wiped clean, it will look like this. NOTE: There is ZERO step in the flow path to the turbos inlet airflow.... unlike other "copy" products out there.
    [​IMG]
    [​IMG]

    Next, trial fit the tip onto billet adaptor to take note of any parts which may need trimming to suit your particular induction setup.
    TIP: the top may need to be trimmed approx 40mm. Check this, as this wil vary between induction kits & Oe airboxes

    N75 outlet will need to be trimmed approx 1/2 its length.

    Use a sharp craft knife for best clean cutting results. TIP use the 70-90 hose clip clamped onto the hose to act as a cutting guide to keep a nice neat trimmed edge.

    Once satisfied the TIP is correct length, fit the lower 70-90 clip onto the TIP lightly nipped so as it wont slide round but not tightened as such with the clip pointing up at 3 o'clock position. See picture below
    [​IMG]

    Once satisfied its rotated correctly, tighten the hose clip at the lower clip on the adaptor.

    Fit the DV, EVAP, N75 and oil breather pipes to the TIP. TIP use washing up liquid to help slide them on. do not use oil lubricants on these pipes as they may well slide off. I dont ever use washing up liquid or any lube on the large clip onto the billet part. This needs to be tightened and not lubed as again, it could slide off. Note where I have pictured the clip position.. Please do the same.
    [​IMG]
    [​IMG]

    Fit the MAF into the TIP, tighten... Check the maf fits the rest of your induction ok..

    Couple of example fitments below.. B5 full kit type install & Neuspeed heatshield + Jr below that
    [​IMG]

    [​IMG]

    [​IMG]



    All should be ok.
    Last edited: May 8, 2012
    #1
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  3. fran-s3
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    fran-s3 Active Member VCDS Map User

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    [Jan 5, 2012]
    Awesome guide thanks Bill. Lastly I hear people warning not to over tighten the jubilee clip on the Jetex filter neck as some have experienced it tearing after a while.
    #2
  4. JtotheD
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    JtotheD Events Moderator

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    [Jan 5, 2012]
    like me. :( silicone sealant has worked a treat though.. for the time being. great write up though I could have done with this a month ago!! haha!
    #3
  5. superkarl
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    superkarl MAN OF STEEL

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    [Jan 6, 2012]
    thought id add my experience.

    firsstly after fitting the billet adapter i just could not get the TIP to sit tightly over it. in trying to get to the jubilee i was bending the TIP to get to it which was popping the TIP off, no matter how tight i got that clip, it would eventually slide off...WITH sealant on the tip-adapter! i was using a variety of screwdrivers mind, not ring spanners (didnt have one so small).

    so what I did, was work out my 2 + 4 o'clock position of the grub screws, and also work out where the tip would be and what angle (pushing the parts on and mocking up doesnt take long, just visualise where the maf/filter would be and what angle), and put the TIP on the adapter, off the car. tightening the jubille as tight as i could pretty much. it was snug, no sliding off the adapter.

    i then put the whole lot on the turbo, making sure the grubs were at there 2+4 oclock positions. i could get to them with the 2mm allen key by bending the tip out the way (it wont pop off the adapter anymore).

    then its all tight and ready for the DV, N75, breather + esp.

    Now i started this job at 1 o'clock. by 4 o'clock it wasn't fitted because of my trouble getting the bottom jubilee tight without the tip sliding off (i did do a couple other jobs while i was down there but still)

    after changing the assembly procedure i had it fitted and tight in about 30 minutes. i was incredibly frustrated having taken 3 hours to realise.

    whilst doing it i imagined that the V1 TIPs would have been a hell of alot easier because they are 3 piece. but the 1 piece was tricky as its so big.

    just a heads up for anyone encountering problems. hope it helps.
    #4
  6. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jan 6, 2012]
    Never had issue on sliding the tip onto the billet piece. they dont slide off when slid on fully.. they simply cant. loads of land for them and the clip when pushed on fully. I dont advise using washing up liquid on this piece, but it would help, BUT you would need to allow time for it to dry off before tightening the clip else I imagine it would then slide off much easier.

    Flexi head 7mm hose do a upper is handy or small 1/4 drive ratchet with 7mm socket is what I use
    #5
  7. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jan 6, 2012]
    yep.. dont tighten the JR's clip too tight no.. Its thin and can (and has) cut into the neck of some filters. The "feel" from some of the clips is'nt great. So long as its tight and wont slide off (which is pretty much how it is when slid onto the maf without clamp) its on well enough for just a little extra clamping from the hose clip.
    #6
  8. superkarl
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    superkarl MAN OF STEEL

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    [Jan 7, 2012]
    Trying to access the clip I was pushing the tip out of the way which was levering it off the adapter.

    But as you say a 7mm socket or ring spanner and my arm wouldn't have been in the way like when trying to use a screw driver.

    In the end though I did it very quick putting the tip and adapter on assembled.
    If I was to do it all again I'd say u could do it in an hour.
    #7
  9. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jan 8, 2012]
    it take me an hour so sounds spot on.
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  10. GrantP
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    GrantP New Member

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    [Apr 29, 2012]
    How large is the difference in airflow between the Jetex filter and the OEM air box with a green filter?
    #9
  11. Schlaag
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    Schlaag Bwah

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    [May 8, 2012]
    No trimming for oe airbox?

    i beg to differ!

    ive had to take 20mm off the turbo inlet side of the hose and the hose STILL kinks when squeezing it back to it over the airbox!

    80mm all the way through.. then it kinks and is no better than standard!

    unless i have a dud hose aswell as the adaptor!

    nothing fits with this hose.. everything is well off!

    I cannot fit this without it kinking!
    #10
  12. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [May 8, 2012]
    edited the instructions now to confirm trimming
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  13. mcpickering
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    mcpickering Member

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    [Nov 8, 2012]
    sorry if this is the wrong place, but i have just bought one of these, off a member and it doesn't have a jubilee clip for the N75 one, what size clip do i need for this?

    Thanks.

    James
    #12
  14. m19lte
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    m19lte Member

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    [Apr 18, 2013]
    Just an update really. When your doing up rubber/silcone hoses and you need some lube, I find a little bit of hair spray works a treat ! And when it dries it gets a right good grip/seal (old trick we used to use for putting grips on bmx bikes ;-)
    #13
  15. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Nov 19, 2013]
    further TIP..
    oil breather pipe into TIP.. I remove the male male barbed connector off the factory hose and file off the barb which goes into the TIP.. Lube with washing up liquid and push it in.. Its very tight but once in, hose clip done up, all is good.

    Trimming at MAF end requried approx 40mm remove depending onto what induction setup you are fitting it to.
    #14
  16. dave5551
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    dave5551 Work in progress

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    [Jun 5, 2014]
    Just fitted one on my 3 took a while to get the adapter on but once on then a realised the problems had to re hose my dc and oil catch pain in the ass anyway here it is
    #15
  17. Drue1
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    Drue1 Member

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    [Jul 13, 2014]
    How much is this kit ?
    #16
  18. dave5551
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    dave5551 Work in progress

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    [Jul 14, 2014]
    Mine was like 70 odd quid mate off eBay didn't bother getting badger 5 one as there over 200
    #17
  19. dave5551
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    dave5551 Work in progress

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    [Jul 14, 2014]
    #18

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