I started to work on the intercooler yesterday and today. I probably wont finish it for another week or so since I have limited time with the little man always running around now, haha. Anyway, my goal was to cut off the passenger side end tank and weld it to the other side along with a block off plate to divide the two end tanks in half. I wanted both inlet and outlet tanks on the same side since running 3 inch i/c piping would be a fuck load easier to do now. So, here is thus far the process. Also, to keep in mind, this is the first time I am tigging aluminum together...what perfect timing to start a shit load of new projects I have coming.

So, to start off after I had cut the intercooler up, I picked up a sheet of 1/8" thick 6061 aluminum. And of corse, you MUST drink a Monster before and during the fabrication.


The first piece welded to the intercooler on the top. This piece is 4" long and welded at a 45* angle.



Bottom piece welded. Same 4" length, however I angled this one more of like a 35* instead of the 45 like the upper.


Both upper and lower halfs welded to the i/c.


Middle section cut and welded in.


And the last thing I did was cut the end piece for one side and got the long bead welded to the intercooler.



Now, I need to run up to to Sears and get a 4-5" welding clamp So I can clamp the sides down to the center section so it does not warp when welding it together.

More to come this weekend hopefully.