I have a BMW turbo diesel intercooler with plastic end tanks that I'd like to remove and weld aluminium one's on. Anyone know if I can find any step by step on how to do this? (I did a search and returned the link below, but the pics are missing!)
https://honda-tech.com/zerothread?id=1003110

Another question please... can I just use my arc welder to do this? (looking at about 1bar boost max). I've also heard that the cooler is galvanized, does this complicate things?

This is the exact intercooler I have:

 

by arc you mean stick? i wouldnt... youd burn right through... or if its mig, you can get aluminum wire, but i think youle have to do some preheating, and i guess its pretty hard to do aluminum welding with a mig... (never done it myself... and if tis galvinized... make sure youre in a really well vented area... those gasses can kill ya

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by 97EK9hatch &raquo;</TD></TR><TR><TD CLASS="quote">make sure youre in a really well vented area... those gasses can kill ya</TD></TR></TABLE>

They most likely won't kill you, but they will make you wish you were dead

 

and they make a mess with the **** that flies off of them, more than normal

 

I've personally never seen aluminum rod for smaw. i don't think its even possible

youre probably better off to take the cooler and the end tanks in to a machine shop or welding shop and have them tig it for you.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Keyhole &raquo;</TD></TR><TR><TD CLASS="quote">They most likely won't kill you, but they will make you wish you were dead </TD></TR></TABLE>

They can and will kill you if you are exposed to them for long periods of time. You can also add the fumes from plasma cutting stainless steel.

 

eh, it'd take a lot of it. But i'd hate to find out HOW much!

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by cua0 &raquo;</TD></TR><TR><TD CLASS="quote">I've personally never seen aluminum rod for smaw. i don't think its even possible</TD></TR></TABLE>
It does exist, but is rarely used because mig and tig are so much better for aluminum.

This intercooler is likely galvanized steel. I have seen some similar to this closeup. I can tell you that it is very far from a worthwhile venture...even if you get the intercooler free!!! It will be a really shitty job and will look like it when you're done.

I had a couple like this and I threw them away. If you want to use the thing, just use it with plastic tanks...paint them or something so they look like metal.

 

Well, you're dead right there, did get it for free. Problem is that I've heard that the plastic end tanks can leak, and also they wont fit properly past the rad. because of the angle of the tanks.

So overall you guys reckon that using a stick/arc welder would be a complete waste of time? I should get a mig/tig? I was under the impression that a lot of materials can be welded with arc welders provided you have the correct flux and rods?

 

The biggest problem is that stick welding is the worst method of welding thin materials. You will likely just blow holes all in it if you try stick welding it.

Sometimes things are free cause they suck....which is the case here. Nobody gives away Spearco intercoolers.

If you want to go cheap, get an old Starion intercooler and pop it in. You can probably get one for about $100. They have metal end tanks.

 

Problem is I live in South Africa, we didn't get that.... but possibly I could sell the cooler to some dude with a beemer... maybe it has value in that way? Thing is the cooler is perfect, it fits perfectly into the bumper (length and height).

But you reckon it can be done by a professional? I'll even build the tanks (cut the ally out and tape it together or something).

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by FranknStein &raquo;</TD></TR><TR><TD CLASS="quote">But you reckon it can be done by a professional? </TD></TR></TABLE>

I am a professional, and I would not do that job for myself or anybody else. The amount you'd have to pay to have it done would exceed the cost of buying a better intercooler.

Why not use it like it is?

 

Boet,
There is definitely someone in boxburg that could do it. The problem is your going to spend over R1000 to get it done. I'm going to agree, either use it or get something else. Dont **** itup!

ALso my uncle has a 330D with that intercooler and he has boost set to 1.5 bar. I am pretty confident it should work in most applications

Cheers
ex Joburger