#106029, "Started the intercooler fabrication." Mar-06-09 01:45 PM by eclipse982nrRST
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.
#106030, "RE: Started the intercooler fabrication." In response to Reply # 0
Nice welds!
Erik P. Official 2GNT thread Hijacker Some say that he's driven over more Covenant than he's shot, and that his grenades aren't where you'd expect them to be... All we know is, He's not The Stig... But he is The Stig's Spartan cousin!
#106033, "RE: Started the intercooler fabrication." In response to Reply # 3
how much does welding the end tanks on yourself save in $? curious.. how much did the core cost, and where'd you obtain the aluminum sheets for fabrication?
Outside of Corona: "That sucks, peace out..." (jamie walks away)... "Sweeet, what we doin?" -Zac Tim's garage (prior to motor install): "Im gonna smoke real quick, that way if you fuck up I am already nicotined up" -Tim
#106035, "RE: Started the intercooler fabrication." In response to Reply # 4
Ebay intercooler = $125.00 Filler rod for tig = $12.50 Cutting off and fabrication new tanks = $5 for griding discs. One 6061 1/8" aluminum 24"x24" sheet = $30.00
So, under $200 as compared to buying a same side inlet/outlet intercooler that is smaller in size, about half the size actually from CXRacing, I saved about 200 bucks.
#106039, "RE: Started the intercooler fabrication...Updated." In response to Reply # 5
Okay well the i/c is mostly done. I am going to finish grinding the edges later in the week and then polish the end tanks and flow plate. Here are some pics.
Then I started to weld all the piping together. I later ran out of gas so I could not finish to weld the BOV flange on. This pipe shown will still get 2 mounting brackets to it, and also will connect to a 90* coupler to a 180* pipe to the intercooler.
