Well I just finnished up my intercooler and we ran into one clearance problem on the upper inlet which wouldnt allow us to get in and weld it so there is about 1" of a 1/8" gap that is open, and I was wondering if I prepped it and put some JB weld over it if that would keep it sealed up too about 30+ psi or should I just find someone with a smaller torch that can get in there? Thanks.






Modified by BB6-213 at 5:59 PM 5/30/2007

 

You better get a smaller torch and weld that becuase JB weld will not cut it.

 

Yeah, I think thats what I am gonna have to do.

 

finish the weld. looks good so far.

 

cut it apart and do it properly without the clearance issues..

 

would solder work?? (please dont make fun of me)

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by cua0 &raquo;</TD></TR><TR><TD CLASS="quote">cut it apart and do it properly without the clearance issues..
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Did you ever think that maybe it was built like that because if clearance issues in the first place. Maybe I will just have you make one for me next time so I can see how an intercooler is made "properly"

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by BB6-213 &raquo;</TD></TR><TR><TD CLASS="quote">Did you ever think that maybe it was built like that because if clearance issues in the first place. Maybe I will just have you make one for me next time so I can see how an intercooler is made "properly"</TD></TR></TABLE>

I understand routing can be tricky and there are always restrictions, but the design of the inlet end tank should be re-thought. First off, you've got a tight 180 degree turn that is going to induce pressure/velocity drop. Second the volume of that end tank looks pretty small your not going to get much flow to the lower half of the fins. I hope your not looking for big numbers for this setup, because i don't think its going to perform. If you are planning on a small turbo setup, then I think the intercooler is oversized and you could easily gain some space for routing back by selecting a smaller core. The inlet side just looks half assed to me, but to each his own.

 

Pull the tungsten out a bit more and turn up the flow a bit. It would also help if you had a back cap for your torch. It allows you to get in tighter spots.

 

Build a few like this. you may not like it but we weld that part on the inside before the rest of the tank is built. So I will say cut that section off and reweld it, you don't have cut the whole thing off just the "neck".

 

sure, i'm pretty expensive though.


the guy that said to weld it from the back side before you weld the rest around it makes a good point.
just something to think about when you design your end tanks you should also plan how they're going to fit together and be welded in which order.

 

weld, no glue will do the same job!

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by tepid1 &raquo;</TD></TR><TR><TD CLASS="quote">Pull the tungsten out a bit more and turn up the flow a bit. It would also help if you had a back cap for your torch. It allows you to get in tighter spots.</TD></TR></TABLE>

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by monster007 &raquo;</TD></TR><TR><TD CLASS="quote">Build a few like this. you may not like it but we weld that part on the inside before the rest of the tank is built. So I will say cut that section off and reweld it, you don't have cut the whole thing off just the "neck".</TD></TR></TABLE>

Thanks guys for the help. I will deffinatley do that if I make another. I have a buddy with a pencil torch that is gonna finnish up that gap for me on friday, so I got it covered. And about the design, I actually got the dimensions from a spearco tank and minus the inlet not being cast aluminum and smoothed for flow it is the exact dimension, and I think spearco knows a tiny bit about intercoolers. And if it does end up being a problem, I can make a tank with more volume, but thanks to you that helped me with my question.

 

do you have a gas lense? If you do you can pull the tungston out pretty far.If you don't have a gas lense it wont matter how high you turn the gas up it won't work.
But by looking at the picture you should be able to weld that easy.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by monster007 &raquo;</TD></TR><TR><TD CLASS="quote">Build a few like this. you may not like it but we weld that part on the inside before the rest of the tank is built. So I will say cut that section off and reweld it, you don't have cut the whole thing off just the "neck".</TD></TR></TABLE>
ditto...i do all my end tanks like this now. and intake manifold plenums.

 

You dont need a smaller torch, you can use a longer tungsten

 

Got it welded today, just a really small cup and it did it just fine.