AAZ/ JX Intake Solution Needed!

[Team WorldTour]

Hello again friends. I'm having a new(ish) issue with my engine. I've had this issue before, but can't find the thread for it. It has to do with the Turbo Intake Elbow:

I had this issue while driving on the Autobahn last year, the rubber got so hot, that it collapsed under the vacuum
I was driving up a hill, full throttle, and it just didn't want to move. When I looked in the mirror, I could see plumes of black smoke billowing out (think ~20% of rolling coal). My solution at the time was to epoxy some steel box stock into the elbow, to hold it from collapsing completely. That worked great, until last month when I was giving the van a pre-holiday inspection (also replacing the intake and exhaust gaskets and bolts).
Upon inspection of the elbow, I found that the epoxy didn't hold, and the box stock was laying loose in there....
So, I welded it into a 'T' shape, and drilled a bunch of holes in it for air flow, and stuck it back in there.
I had thought that was the end of it.
Here I am, in Italy (very hot and clear, and yes, I have a sunburn, thanks for asking!), and the problem has returned.
Through trial and error, it happens when the engine is hot (10-15 minutes on the highway), and then only in top gear, at full throttle (again). As it is, I can only drive 100-105kph. Speed limit is 130, the van is capable of 125.
I'm wondering if anyone has come up with a solution for this other than this:

I've written to Brickwerks to see if this would fit my application, but at £125, I'd like to look around before I pull the trigger.
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1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

[Zeitgeist 13]

Check your snorkel tubing up the pillar. I had a similar issue with low power and excessive smoking due to a collapsed snorkel.
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Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[Team WorldTour]

Thanks for the heads up, mate. I haven't inspected that bit in two years, not since I replaced the old powdery foam hose.
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

[Team WorldTour]

Ok, update and maybe an end to this thread (at least until I get back to Germany!).
We've made it to Venice, and I took the snorkel hose out. I could see the crease in it where it had collapsed. The inside mesh was rusted out and in bad shape. I opened my air cleaner, and brushed out the rust dust I found in there.
Unfortunately, the air hose didn't want to come out, and as a result, is now in three (unusable) pieces on the ground.
Since I'm not planning any water crossings on the way home, I think it will be alright to drive. I'll just have to find a solution later.....

Thanks again for your help, Samba.
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

[Team WorldTour]

Ok, as promised, here is a write-up of our return trip.
As stated, I removed the oval snorkel hose from the D pillar. I could see that this had a bend in it, and the metal mesh inside was rusted and soft.
This did not change anything at all.
What did change came with ambient air temps. As we drove up into the Alps, the air temp dropped a bit and I could get a little more on the gas before the smoke came.
When driving at low speeds, like up hills, I could stand on the gas and not get the black smoke. However, out on flat land, I could accelerate to about 80% of the gears given top speed before it started to smoke again. So, logically, it is the engines speed, not the fuel given.
With no other information, I'm leaning towards the elbow softening in the heat and collapsing.
I've now got, on hand, the Brickwerks air intake pipes, both upper and lower.
But I'm wondering if there is also a vacuum hose I should inspect/ replace as well?
Anybody?
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

[ALIKA T3]

I`ve never seen one of these elbows going so soft to collapse

I ran some bad frankenstein set ups, no intercooler and what not back in the days, never had that happen.
Is your exhaust homemade? heat radiating to it? Was the elbow a VW piece?

No vacuum to check related to it, just make sure your cranckcase breather system is all good
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Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget

[?Waldo?]

How old is your air cleaner element?

[Team WorldTour]