Making an Intercooler... got some Qs

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Old May 7, 2006 | 06:00 PM
  #1  
Boilermaker1's Avatar
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Default Making an Intercooler... got some Qs

I'm fighting some space constraints, which is why its got "pancaked" end tanks, but I can't go more than 9.5" high without the IC coming through the bumper cover. 18x6x3 core, 2" inlet, 2.5" outlet. Need same side in/out because of A/C compressor.
I've seen some of these long end tank ICs with chamfered tanks on the far end, presumably to keep the airflow moving by shrinking the volume, but I was also of the impression that slower IC flow was more beneficial to cooling, and any boost level can be corrected out with a boost controller. Which leads me to the question of which would be a wiser option? Square tanks or Chamfered tanks?



???
I know I'm giving up a little by not having full height tanks, but I just can't make them any higher. I'm hoping the little end reservoirs help the issue a little bit, but I'm not out for as much power as I can make, I just want the car to be fun and be able to screw with it.

I've got the core already, as well as some .125 6061 sheet to fab end tanks with. I know how to do the work, problem is I don't have the tools to do it... probably one of the biggest downsides to living in a city. I used to make crap all the time at school, but I don't have access to a machine shop anymore. Anyways, can someone recommend a fab shop or can anyone around the DC area help me out with this and TIG it up? I have dimensioned drawings, I have no problem making templates for the end tanks from cardstock, etc, or helping out. There's some charge pipe extending that would also need to be done, I have SS tubing for that too. I'm not looking for a freebie if someone offers to help me.
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Old May 8, 2006 | 06:12 AM
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Anyone? Help?
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Old May 8, 2006 | 10:46 AM
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what car?

have you looked into an air to water IC
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Old May 8, 2006 | 11:49 AM
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Its a 2002 Civic.
The car sees occasional track (road course) time, so I'd like to avoid a Air/H20 IC as I'm not seeing a finite amount of water in the system staying cool too long if the car's under boost for a fairly extended time.
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Old May 8, 2006 | 12:58 PM
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You should have an inlet @ the top corner and bottom opposite corner that is how that should be done, but hey I'm an idiot .
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Old May 8, 2006 | 06:15 PM
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Well its not difficult to flip the in and the out on top and bottom, but the outlets can't be on opposite sides for the reasons above.
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