#106029, "Started the intercooler fabrication." Mar-06-09 12:45 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 # 8
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.
Finished the intercooler and piping today at lunch time. All thats left to do is to get a bov flange, an air filter and get the piping painted black and polish the intercooler plate and end tanks.
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
#106077, "RE: Done." In response to Reply # 17 Mar-16-09 01:44 PM by Mike431635
Sick. Gonna route my piping about the same way, but gonna run the pipe to the throttle body a bit closer to the head. Naturally, it won't look as hot as that though. And I did get my intercooler this week with the inlet & outlet on the same side. However, it's not divided like yours. What are your thoughts on efficiency of this design? My thinking is, the charge will follow the path of least resistance so the entire IC will be pressurized at 8psi and since the inlet is also pressurized at 8psi, the air will automatically take the outlet and thus will be just as efficient as a 2-sided setup.
Am I correct in thinking this, or is there more to it? What I DON'T want is the air just flowing in one way and out the other without even entering the main portion of the intercooler. My IC is only 8" tall though which kinda sucks.. so maybe I'll order a much larger one, cut off the end tank with a plasma cutter, and weld in an aluminum divider in the end tank. I have access to a plasma cutter, TIG, and MIG machine. Might as well conquer my fear and learn.
Mike, you are a true craftsman. Awesome work bro! Your aluminum welds are rediculously clean.
I was just thinking how awesome it would be to steal your motor and turbo to put it in my car..... Then I realized it'd prolly be easier to just take your whole front clip so I could save myself the work of trying to redo what you have perfected. lol.
Originally posted by thedawg
I ran 15-18psi on my stock a604 for about 30k miles then it broke. It makes cool whining noises now.
Originally posted by ThePerfectShift Mike, you are a true craftsman. Awesome work bro! Your aluminum welds are rediculously clean. I was just thinking how awesome it would be to steal your motor and turbo to put it in my car..... Then I realized it'd prolly be easier to just take your whole front clip so I could save myself the work of trying to redo what you have perfected. lol.
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and polish the intercooler plate and end tanks.
