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Diy CXracing intercooler *56k warning*
25 Attachment(s)
I wanted to get rid of my old intercooler setup because
Attachment 205264 1. It was ugly 2. It rubbed on the belts sometimes 3. hot side recieved higher temperatures due to passing in front of the fan. Attachment 205265 Tools required... 1. Safety glasses 2. Ear plugs/muffs 3. Protective clothing for welding 4. A chop saw or some way to cut the pipe 5. Welder and filler rod (also stainless steel brush to clean aluminum) 6. Dremel with sand paper ends/cut off wheel 7. Brain Tools helpful... 1. Table vice to hold pipes in position 2. Sharpie pen to mark pipes where to cut 3. Music to rock out to while your fabbin. Material list... 1. CXracing intercooler kit off ebay CXRacing Intercooler + Piping Kit ACURA RSX TSX MIATA:eBay Motors (item 190310932189 end time Jun-06-09 18:49:07 PDT) 150$ 2. Flat bar to mount intercooler = scrap 3. Pipe pieces = scrap 4. Extra flapper wheel/ sanding/ cut off disks = 15$ (for the whole kit) You assume all risks and i will not be held liable for you screwing up your car if you do This writeup was done on a car without A/C or PS. Im pretty sure it could be done with PS but the intercooler mounts to the AC brackets. Anyway... First i cut off some of the condensor bracket so that my intercooler would sit up as high as possible. Attachment 205266 Then i marked where my holes were and welded 2 brackets on the end with a slight angle (to match the angle of the radiator) Attachment 205267 Attachment 205268 I marked out where the holes were and drilled them out Attachment 205269 Heres what it looks like from the front Attachment 205270 And where the bracket ties in Attachment 205271 Next i clocked my turbo down using a rubber mallet. It ended up being over a 90 so that the pipe would clear. (Be careful! Get some pliers to compress the snap ring while you beat on it) Attachment 205272 Grab one of your 90's and mark out your first cut from the turbo. This one had to be cut shorter or else it would hit the coolant return hose. Attachment 205273 Next move further along and mark your next cut. You will want to angle this cut slightly as this is where it starts to go south Attachment 205274 Grab another 90 and mark out where you want it to land on as this will turn down. Be sure to get the right angle you want so that its verticle or a little over for an easier transition ( i had to cut it twice before i got it right ) Attachment 205275 See? Attachment 205276 Got it tacked on now for the intercooler side Attachment 205277 Grab one of your 45's and chop it off right at the end of the bend Attachment 205278 Grab your 75 and chop it so that its heading straight up ( you will have to shorten this piece ) Attachment 205279 Mark it cut it http://i692.photobucket.com/albums/v...s/P6110018.jpg There it is in position Attachment 205280 Take one of your drops and cut a very small section so that it will be beaded. Make sure you angle this cut as close as possible to the upper pipe so that there in line. ( i actually grabbed a longer pipe so that it was safer/easier to cut) Attachment 205281 All tacked togethor Attachment 205282 This is the last test fit before welding Attachment 205283 Ready for the heat! :giggle: Attachment 205284 Welds Attachment 205285 close up Attachment 205286 Other pipe Attachment 205287 All done Attachment 205288 Hot side is all done. Tomorrow at work im gonna make the BOV flange as well as the small pipe for the IAC. |
Nice! Using wire or tig for this?
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Very nice build, NW turbo's FTW!
Question:
Originally Posted by elesjuan
(Post 418516)
Using wire or tig for this?
Welder and filler rod And the question should technically be MIG or TIG, as there are wire feed TIG's as well, in some ways they're a little easier (point and shoot) but can't be nearly as pretty if you're good with a filler rod. |
Looks good. Surely beats paying out the ass for a prebuilt kit, when you can do this for under $200 (or whatever you paid). I wish a had a MIG or TIG machine for myself, I would be welding all kind of stuff. Actually, I may buy myself one for my birthday.
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Originally Posted by curly
(Post 418519)
Very nice build, NW turbo's FTW!
Question: Answer: (so TIG) And the question should technically be MIG or TIG, as there are wire feed TIG's as well, in some ways they're a little easier (point and shoot) but can't be nearly as pretty if you're good with a filler rod. I did somehow miss his "welder and filler rod" part of the post.. |
Wish i knew how to weld.
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Originally Posted by jobambo
(Post 418549)
Wish i knew how to weld.
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Sorry i guess i should of clarafied. Im using a Miller TIG Welder - Dynasty 200 DX AC/DC TIG/Stick with 4043 filler rod.
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That looks pretty good! Welded charge pipes sure beat all the cobbled together couplers and bends that make up my piping.
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Fuck me running sideways in a handstand! 2800$!!??
I can has, Yes? |
i actually bought it 2 years ago when it was 2399 shipped no tax. Since then miller has upped the pricing.
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28 Attachment(s)
So i finished the piping today at 7 but had to get ready to see The Hangover. BTW that movie is hilarious and i highly reccomend seeing it.
Anyway back to the intercooler. I went to Central Welding to pick up up some more supplies and saw some drill attachments that would be great. Added 10$ to the tab. Got my boss to cut out the flange on the CNC router Attachment 205226 I marked where i wanted the BOV Attachment 205227 Started drillin holes around the perimeter Attachment 205228 I used one of the drill bit sanding attachements to sand it nice and smooth Attachment 205229 I used a hole saw at work to make a nice fit Attachment 205230 Sanded the flange nice and smooth Attachment 205231 Cut the pipe shorter so it wouldnt sit too high Attachment 205232 That drill sander works wonders Attachment 205233 Test fit Attachment 205234 Welded Attachment 205235 What the BOV looks like mounted Attachment 205236 Heres me welding. Im not a hillbilly; those are my work clothes and they keep me nice and cool in the hot shop. Attachment 205237 Okay now on to the cold side piping. Grab one of your 90's and mount it on with the shorter side to the intercooler. No cutting required for this piece. Grab another 90 and cut it short and leave the bend all there. Attachment 205238 Heres the only uncut piece of this piping kit Attachment 205239 Under side Attachment 205240 figureing out where to cut . Attachment 205241 Marked it out and cut it Attachment 205242 I decided to make the cold side 1 piece so theres the fit up and marked the line Attachment 205243 All tacked togethor Attachment 205244 Marked the hole for the IAC valve Attachment 205245 Took some 3/4" OD tube and test fitted it Attachment 205246 Got it tacked on Attachment 205247 Last fitup before final welding. Attachment 205248 All welded up, Notice the beading on the IAC valve. It wouldnt be a tight fit without it. Attachment 205249 Heres what the BOV looks like mounted on the hot side Attachment 205250 All done with the intercooler. Just need to get an IAT bung welded on and fab a bracket so that the wastegate has something to clamp too Attachment 205251 Attachment 205252 Attachment 205253 Overall it took about 5 hours to do for my first time. I have 3 pipes i didnt use. Also i didnt use lots of the couplers and T-bolts. When i take the turbo off again im going to weld a piece of 2 1/2" aluminum over it so i can actually get the right coupler and a T-bolt around it. I must say that my engine bay looks much better/cleaner. I got a K&N air filter coming in the mail to compliment my new piping. The old one i smashed down so it would fit. Notes... I used a abrasive chop saw (used for cutting steel) and would of made much better cuts using a band saw or a chop saw with a carbide blade. Tack everything togethor first and test fit prior to final weldout. "Takes just as long to do it right as it does to do it wrong" -My father I used a water hose to spray inside of all the pipes before final connection to get all the aluminum shavings out. Overall i spent approx 170$ for a full intercooler kit and was very easy (although welding for some might be a problem) Enjoy! |
people who weld are the coolest!
-G- |
Someday i'm going to drive down to renton and sbk is going to weld my intercooler piping with his fancy schmancy tig =P
The difference between his CXracing IC setup and mine is that i've got 200% more couplers holding everything together. |
7 Attachment(s)
even though the intercooler piping is done i figured id remake my intake piping with the leftovers.
I took the last 75 i had and cut it off right after the bend. Then i took one of the leftover drops from a previous cut that had some bend on it and cut them Attachment 205211 Took the original greddy tube and chopped it off at the very end so the air filter can clamp on it Attachment 205212 It was fuckin hot so i dropped it Attachment 205213 All welded up http://i692.photobucket.com/albums/v...s/P6130064.jpg At this point everything was good to go and i turned the key and started IMMIDIATELY whcih was sweet. But my old fuel map was tuned on 7psi of fuel now im at 65. I turned off the car turned the key to the ON position to change the table back to stock.. I heard some hissing and smelled fuel. I turned off the car and holy shit my fuel feed line busted off. Attachment 205214 Attachment 205215 Attachment 205216 Probably dumped 2 cups of fuel on the ground atleast. Went to shucks and got some hose clamps and double clamped that hose so no more bursting. I made quick wastegate bracket from some scrap aluminum i had laying in the back. Attachment 205217 |
Your recent diy threads are awesome. thanks for taking the time.
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Originally Posted by sprayed
(Post 419469)
Your recent diy threads are awesome. thanks for taking the time.
I know i like lots of pictures looking at threads. And if that helps one fellow MT.netter with his install then it was worth it. |
Me needs to learn welding. Aluminum. But welding steel is first.
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bump.
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What the ---- are you bumping this for. Yes, it's a cool thread, but come on.
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