Installed the charge pipe and am having an issue with frame clearance on the outside of the second 90 degree bend coming off the intercooler. I'm afraid contact/vibration at this point will eventually cause a tubing wall failure. Any simular experiences or hints on installation clearance?
Thanks, Ray in TX.

 

Could you get a pic of it? It maybe one of the pipes are not in all the way in one of the couplings.

 

The bend that comes up in front of the radiator or above the engine?

Also which charge pipe? I'm assuming the hot side, since nobody really changes out the cold one.

I'm going with Rob here, something isn't pushed all the way in.

 

Sounds like you got a kit for a cobalt not a hhr. Their website states that the hhr kit comes with an angled coupler to clear the frame

 

It's the hot side pipe that comes up from the left side of the intercooler, behind the radiator. It's not the first bend off the intercooler nipple, it's the next bend upwards. The outside radius is hard against the frame member. I considered the special offset coupling from Dejon, but I believe it's for the cold pipe. Can't get the end of the pipe and the intercooler nipple to "square up" so maybe the offset coupling is the cure. I'll call Dejon. Also, had some trouble with blowing couplings of (Trifecta tune - 24psi, T-bolt clamps). Did the clean with brake cleaner and hair spray before assembly. No more problems with couplings popping off!
Thanks, Ray in TX.