Here is my kick at the cat making an intercooler. A couple of us pitched in and bought a large diesel truck intercooler. I cut it into 3 and am doing end tanks. This is the first one. The core was a little beat to begin with but It turned out ok. Welds are not the prettiest but dat **** takes lots of practice!
Core 30" x 6" x 2"

 

nice corduroy pants
how much boost ?

 

hell ya, finally, someone that diy's with aluminum. that thing is suuuuper long too. hope it doesnt leak.

 

u have a lot of swords

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by javierb14 &raquo;</TD></TR><TR><TD CLASS="quote">


u have a lot of swords </TD></TR></TABLE>

yeah no **** yo!

 

I got a bunch of wierd stuff from a late uncle!

 

replacement killers

 

for diy

if you do it again I'd make those endtanks angled (maybe like 1 45 degree cut to get rid of the sqaure edge) for better flow characteristics

to your avatar !

 

Man, people notice the wierdest things!! I surprised that no one noticed that you're girlfriend is naked in that one reflection!!

But yah, that intercooler is on longass mamajohamba!!

 

looks good whoooot can wait to get my LEGEND Intercooler

 

looks good man, what the welder cost you ? what kind ?

 

Nice.

Please comment on what you did to properly clean the old core before welding. Mine is 95% there with 5% of the welds looking like crap due to impurities that could not be controlled.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by J. Davis &raquo;</TD></TR><TR><TD CLASS="quote">Nice.

Please comment on what you did to properly clean the old core before welding. Mine is 95% there with 5% of the welds looking like crap due to impurities that could not be controlled.</TD></TR></TABLE>


Ya, contamination is a bitch. All I used was a s.s. brush on the ic itself. I contaminated my rod so many times I was getting pissed off! But tig welding shaky hungover isn't the best idea Anyways, all I used was thiner to take the oils off (the aluminum tank material) and a stainless steel wire brush. Any time I got contamination I stop, reclean with the brush and keep welding. Seemed to work ok. I know I tig'd a turbo manifold completely for the first time this weekend (usually tig and mig) and I didn't have any contamination problems at all.

I'm using a 30 yr old machine, ac/dc, probably one of the first machines that came with hi-freq. The thing sucks, no amperage control except for the arc welder its powered from. But I figure that if I get good on that machine if I ever buy a nice syncrowave or something I'll kick ***! heh

The design of these tanks was done this way simply because I have extrusion that fit perfectly = less welding. But now that I know i can do it I'll change them to angled tanks. MR8's should be much better.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by legendboy &raquo;</TD></TR><TR><TD CLASS="quote">I got a bunch of wierd stuff from a late uncle!


</TD></TR></TABLE>i see your late uncle had a set of motor mounts

 

looks liek 1/4 of a semi intercooler

 

welds aren't too bad, kinda looks like some of the thin spearco like ic's i've seen on ebay. pressure test that thing for leaks yet? looking good, can only expect better in the future

 

any chance you'll be selling that stuff on e-bay as Anti-Honda-Theft Equipment?

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by legendboy &raquo;</TD></TR><TR><TD CLASS="quote">I got a bunch of wierd stuff from a late uncle!


</TD></TR></TABLE>
are those swords DIY too.

 

Since my thread was bumped I'll post a pic of another ic I did from the same core but this is for my bud's sr20 240.

 

You've got some skills, but the designs are not the most effectient for moving a lot of air. There are a ton of good turbocharging and intercooling books on the market right now. You should pick one up.

nice IC's so far.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by hypa &raquo;</TD></TR><TR><TD CLASS="quote">You've got some skills, but the designs are not the most effectient for moving a lot of air. There are a ton of good turbocharging and intercooling books on the market right now. You should pick one up.

nice IC's so far.
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heh ya, my end tank design is a little limited until my aluminum welding skills improve

 

good job. I'm so ghetto I zip tied my intercooler to my car.

Nick