I started fabricating the tank for my water to air intercooler the other day. It tucks nicely up in the passenger side front corner in front of the wheel. Method for getting the dimensions is pretty easy. I calcuated the rough cube I needed from the cubic inches in 3 gallons. Then I tooks some measurements so that it would fit in the spot I wanted it. Next I cut out cardboard rectangles and taped them up to fit and then test fit the tank on the car. It didn't quite fit due to a little sheet metal so I made a little cutout in the upper part of the tank. Now it fits nicely and ended up holding right at 3 gallons. Now I've got the dimensions to cut the pattern out of 1/8" aluminum sheet and weld together :D

 

Got a little further (time lapse posting)...
Tank is now tacked and partially welded. I still need the bungs and filler on the top from Summit (part# anyone?) before I weld the top on.

Test tank vs actual tank


Tacked up


Inside tacks


Weld closeup


Another closeup weld

 

 

thats awesome looking. I was considering doing the same for a turbo setup when i start it. What are you doing for the piping? COuld you explain in more detail how you are doing this? Thanks James

 

I'm making the piping as well. This is just the water/ice reservior. Core is a PWR 6x10 fed by a gt42.

I'm not sure what you need explained better but if you clarify that I can post more info.

 

yeah sorry if i didnt explain well. i wasnt sure how to word it. The core is what i meant and how you were actually going to be cooling the air. Thanks and looking forward to some more pics when you get it done. James

 

lookin tite keep us up on the progress

 

Looks good.. You may want to put a slant on the bottom to a common drain just incase you ever have to wash out the tank.. Or maybe a removable fitting like a T piece

 

Yep there will be a drain on the bottom. Just haven't got that far yet

 

Just a little update:
Received my bungs to weld on today so I'll be finishing up the project this week. It's fully welded except the top of the tank and the bungs so it won't be long.

 

where did you order the bungs from ??

 

Looks good.

I know it's too late on this project, but I have a suggestion for others, or the next time you make something like this.

Notice how your corners fit in a way that one overlaps the other...
If you make the inside edges of the metal meet, it makes a nice V shape on the outside that you can then fill with weld metal. It makes for a nicer fitup that's easier to weld.

 

thats def a good point for a cleaner more even weld to line up each side to make a v and weld that up thats the way i do all my welds when i come into a situation like this

 

Ya good point Engloid. A couple corners line up like that but most don't. I needed to get this cut quick so I made the pieces a little too long to make them meet in a V. I'll try that in the next tank. Also the very inside corner of the "cutout" piece was damn hard to weld. I got it welded solid but it's going to take some more practice or maybe different lens's to get it really pretty.

 

nice work

 

Got a little farther. Just a few more pieces and i'll be done. More bungs are on order and I need to pick a lid and get it done. The inside corner weld didn't turn out the prettiest but i was happy considering it was my first inside corner ever. Most important part, no leaks. lol






Chris

 

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

I know it's too late on this project, but I have a suggestion for others, or the next time you make something like this.

Notice how your corners fit in a way that one overlaps the other...
If you make the inside edges of the metal meet, it makes a nice V shape on the outside that you can then fill with weld metal. It makes for a nicer fitup that's easier to weld.

</TD></TR></TABLE>

I think I understand that, your talking about so the corner would not be a perfect 90 degree wrap around bend, more of a small gap missing ( basically a v point inward ) and once you weld it, it would be a 90 bend ? Like right now the weld sticks out a tad so its not really a true 90 bend. Am I making sense ?

 

Yeah, that's what Engloid is talking about. It makes a huge difference on how the weld looks when you do it that way. It puts the weld right on the corner rather than on one side and allows for easy penetration since you have a groove to fill.

 

Any tips on how to do the inside corner better next time? The one on the cutout where three pieces all join? I stuck the tungsten out a little farther but it was still hard to get the torch close to the work on the very inside part. I have a limit supply of accessories but it's my work welder so they'll probably order more for me if I know what to ask for.

 

Just need some more practice, shouldn't need anything special to do that weld. It generally takes more heat for that weld, but no special cups or anything. Just a bunch of scraps and practice on them. I don't know of any tips to give on that or i would.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by chrisgvr4 &raquo;</TD></TR><TR><TD CLASS="quote">cardboard </TD></TR></TABLE>

 

Just an update. I got my order in from summit so I just need to punch out the cap hole and weld on the top. I'll post finished pictures before and after powdercoating.

 

i would reccommend pressure checking that before going thru with any other time consuming features u may have in mind, for that tank. hate to see ya powder coat it and it leaks and needs to be welded again

 

Thanks. I filled it up and it holds water. I doubt the tank is going to be under any significant pressure seeing as it's just a tank for ice and extra capacity. I powdercoat it myself at work so I can alway just blast it and redo it should anything be wrong.

 

nice work post some picks of the set up when its done