I want to have the one end tank fliped so that the inlet and outlet are on different sides. I was told before to cut off the weld and just flip it and reweld. Is it worth trying to do it or should I just try to get the company to build one and sell this one?

I have access to a good tig welder and someone that does tigwelding but i don't want to destroy the intercooler trying to remove the end tank, the weld on it now aren't exactly crappy

 

yep, its doable, just make sure you make a good precision cut so it will be pretty flush when you flip it and get it welded. Personally i wouldnt bother with selling it and trying to get another one, but thats just me.

 

So i cut the weld in half or do i gring down the old weld till it is gone? I can see cutting it right down the middle, fliping it and using the existing alum to weld it back together, maybe some filler might be needed too correct?

 

yeah i would just try and cut it down the center of the weld, now it doesnt have to be "exactly" perfect, but pretty close so you can grind a little til they fit together nice and snug, it will make it easier to weld if there are minimal gaps

 

That weld looks pretty close to the header plate. Your best bet would be to use a bandsaw and jig up the IC so your cut doesn't go all crooked.
If you have access to a laser (since you have access to a TIG welder) that would actually be the best way to cut the tank off.
At any rate when you cut the tank off, you'll need to grind the weld down to the same thickness as the parent material, then if the tank is any thicker than .063" grind a bevel on the edges so your welder gets complete penetration.
Good luck!

 

It's not that hard to do but I would cut slightly off center of the weld favoring the tank side to avoid cutting the core at all. I would also insert an air hose into the tank your leaving and have air flowing through the core so no cutting chips have a chance to get into the core itself. They will blow out as they are made. I am 5 miles south of great adventure and build intercoolers all the time. If you need to get it done and don't feel comfortable doing it yourself I can do it for you. It will take about an hour.

bob kasper
kasper fabrication & machine
kfm race cars & components
609-851-2810

 

Yea, i just asked the guy that does all my work like this and he doesn't feel comfortable welding the end tank back on, he said cutting is no problem but he doesn't know how well he can weld the thicker end plate to the thinner core, and he was also worried about heat tranfering to the core and messing it up. So now I'm on to either the company that built it or you KFMRC. Let me know how much you would charge to flip the one end tank, I will have to ship it to you.

 

Just figured i would post up some pics of the awsome job that was done by Kasper fabrication & machine.....


Very happy, thank you once again.

 

Your welcome and thanks again for the chance to help you out and the nice post.

bob kasper
kasper fabication & machine
609-851-2810

 

Wow, that looks like really nice work, good stuff.