I think that piping to the intercooler is going to be tight. From the intercooler to the inlet elbow should be easier. The discharge elbow is an aluminum, 3", schedule 40, weld pipe fitting. It was fun matching it to the discharge housing. I then inserted a 2 1/2" length of the 3" OD intercooler piping into the end and welded in place.
The inlet is a 3" OD cast aluminum 90° from ebay. The flange is a piece of used 1/2" that had some machine marks on it, I hope the judges(?) don't take off points for looks.
I used almost 3/4 lb. aluminum rod. I would keep track of my hours, but I don't do this stuff for a living, lets just say I have a lot of time in it so far.
The reason that I am posting this build is to maybe give you other MacGyvers some ideas to base your builds on, and to show everbody else what a pain in the *** it was.
Pictures:http://homepage.mac.com/michaeldritz/PhotoAlbum3.html
Tomorrow "Where will the intercooler go?"

 

looks good man keep up the great work .

the bend from the discharge elbow to your ic looks like it might be tricky .

im suprised all the whipple junkies havent chimed in yet on your progress , anyway cant wait to see the final assembly and some results !!!

 

I dont have a whipple but I have a Kenne Bell, I like the idea of running the discharge out the pass side of the blower however I have been unsure of how to do so. How did you get the discharge out of that side? I was going to do a LS6 manifold and all that crap but I would rather run it out of the pass. side. Also what are you doing about the by pass valve?

 

Ok nevermind, I seen the Part I pics. Hmmm, not sure I want to do that to my outlet.... Although I am interested in some more pics of the flange you made to mount to the intake.

 

Thanks for the encouragment, ChopperB. If you do yours as a winter project, it still might be done before mine.
What do you want to see on the inlet elbow, 03sierraslt? It's just a flat piece of metal with a 3" hole cut into it, and an elbow welded into the hole. If you want, I'll take it off of the manifold to shoot some more pics.

 

No, no need to do that. I was just wondering where you got a 3in elbow with that tight of a bend? Did you make it your self? Or get it elsewhere?

 

Is that elbow the original whipple inlet elbow just cut off and welded onto a different flange?