Turbosmart 38mm Stainless Steel Profiled BOV Adapter Flange - Universal (TS-0205-2003)

Mount your Turbosmart blow-off valve cleanly and securely with the Turbosmart 38mm stainless steel profiled BOV adapter flange. The TS-0205-2003 is a precision-machined stainless steel adapter flange designed to accept Turbosmart's universal fit BOV range — profiled with the curve of round intercooler piping for a flush, secure fit against your charge pipe. Requires welding to the intercooler pipe for permanent installation.

Note: Requires welding to intercooler piping for installation. Professional TIG or MIG welding recommended. Verify 38mm flange compatibility with your specific Turbosmart BOV model before ordering.

Key Features:

• 38mm stainless steel BOV adapter flange
• Profiled to match the curve of round intercooler piping
• Compatible with Turbosmart Plumb Back, Dual Port, Vee Port Pro, and Supersonic universal fit BOVs
• Stainless steel construction — corrosion and heat resistant
• Requires welding to intercooler pipe
• Universal — suits any round intercooler pipe of appropriate diameter
• 0.12 lbs

Compatible Turbosmart BOV Models:

• Turbosmart Plumb Back BOV — universal fit
• Turbosmart Dual Port BOV — universal fit
• Turbosmart Vee Port Pro BOV — universal fit
• Turbosmart Supersonic BOV — universal fit
• Note: Verify your specific Turbosmart BOV model uses the 38mm flange size — Turbosmart offers multiple flange sizes for their universal BOV range

Specifications:

• Brand: Turbosmart
• Part Number: TS-0205-2003
• Flange Diameter: 38mm
• Material: Stainless steel
• Profile: Curved — profiled to match round intercooler piping
• Installation: Requires welding
• Compatibility: Turbosmart universal fit BOV range
• Weight: 0.12 lbs
• Barcode: TS-0205-2003

Installation Notes:

• Professional TIG or MIG welding recommended for a clean, leak-free weld
• Mark and cut the intercooler pipe at the desired BOV location before welding — ensure the location provides clearance for the BOV body and vacuum line routing
• Clean the pipe surface thoroughly before welding — remove any coating, paint, or contamination from the weld area
• Position the flange with the profiled curve seated flush against the pipe before tacking in place
• Weld fully around the flange perimeter for a leak-free seal — any gap in the weld will result in a boost leak
• Allow the weld to cool completely before installing the BOV
• Pressure test the charge system after installation to verify no boost leaks at the weld or BOV flange interface

Profiled Flange — Why It Matters:

A standard flat BOV flange does not conform to the curved surface of round intercooler piping — when welded to a round pipe, a flat flange contacts the pipe only at two points (the sides of the curve), leaving gaps at the top and bottom that must be filled with weld material. This creates an uneven weld that is more difficult to execute cleanly and more prone to leaks.

The Turbosmart profiled flange is machined with a curved base that matches the contour of round intercooler piping, allowing the flange to sit flush against the pipe surface around its full perimeter before welding. This flush contact makes the welding process significantly easier — the welder is filling a consistent, narrow gap rather than bridging large voids — and produces a cleaner, more reliable weld with less risk of boost leaks. For anyone building a custom intercooler pipe or adding a BOV to an existing pipe, the profiled flange is the correct choice over a flat flange.

Stainless Steel Construction:

The TS-0205-2003 is machined from stainless steel — a material that provides excellent corrosion resistance and heat tolerance for the intercooler pipe environment. Stainless steel is compatible with TIG and MIG welding to aluminium intercooler piping using appropriate filler material and technique, and to stainless steel piping directly. The stainless construction ensures the flange will not corrode or degrade in the engine bay environment over the long term, maintaining a reliable seal at the BOV mounting point.

Turbosmart Universal Fit BOV Range — Context:

Turbosmart's universal fit BOV range — including the Plumb Back, Dual Port, Vee Port Pro, and Supersonic — are designed to be installed on custom intercooler piping via a welded flange rather than using a vehicle-specific adapter. This universal approach allows these BOVs to be used on any turbocharged application with custom or aftermarket intercooler piping, making them popular choices for custom turbo builds, engine swaps, and applications where a vehicle-specific BOV is not available.

The TS-0205-2003 adapter flange is the correct welded mounting solution for these BOVs on round intercooler piping — providing the 38mm flange interface that the universal BOV body bolts to after the flange is welded in place. Once welded, the BOV can be removed and reinstalled using the flange bolts without disturbing the weld, allowing the BOV to be serviced or replaced without cutting the pipe.

Why Turbosmart?

Turbosmart is an Australian manufacturer of turbocharger management components — blow-off valves, wastegates, boost controllers, and related products — with a strong reputation in the performance and motorsport market worldwide. Their BOV and wastegate range is used extensively in professional motorsport and high-performance street builds, and their components are engineered to precise tolerances for reliable performance under demanding boost conditions. The TS-0205-2003 adapter flange reflects Turbosmart's attention to detail — a small but important component that makes the installation of their universal BOV range cleaner and more reliable.

Perfect For:

• Custom turbo builds using Turbosmart Plumb Back, Dual Port, Vee Port Pro, or Supersonic universal BOVs on round intercooler piping
• Engine swap builds needing a universal BOV mounting solution on custom charge piping
• Intercooler pipe fabricators wanting a profiled stainless flange for clean, leak-free BOV installation
• Anyone adding a Turbosmart universal fit BOV to round intercooler piping and needing the correct 38mm profiled adapter flange

Perfect For: Custom turbo builds and intercooler pipe fabricators needing Turbosmart's 38mm stainless profiled BOV adapter flange for clean, leak-free installation of Plumb Back, Dual Port, Vee Port Pro, and Supersonic universal BOVs.

Pro Tip: When positioning the BOV flange on your intercooler pipe, consider the vacuum line routing to the BOV's signal port before finalizing the location — the BOV needs a vacuum/boost reference line from the intake manifold or post-throttle body location, and the flange position should allow this line to be routed cleanly without sharp bends or excessive length. Also ensure the BOV body will clear surrounding components (intercooler, radiator, chassis) when the flange is in your chosen position.

38mm | Stainless | Profiled | Requires Welding: Universal — suits round intercooler piping. Compatible with Turbosmart Plumb Back, Dual Port, Vee Port Pro, Supersonic universal BOVs. Professional welding recommended. 0.12 lbs.

Mount your Turbosmart universal BOV cleanly with TS-0205-2003 — 38mm stainless profiled adapter flange, curved to match round intercooler piping, for leak-free BOV installation on custom charge pipes.