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Old 01-28-2009, 01:19 AM   #1
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Default The intercooler build begins -_-

Ok, so I bought a 26x7x2.5" intercooler off ebay to do the typical DYI intercooler build, but lately have been seeing some very interesting "over the radiator" setups that have really inspired me to go against the flow and try to build an intercooler route that keeps the piping/couplers to a minimum eliminating failure points.

Came in all nice and shiny:


Today after finishing the header, we had some time and decided to convert the typical side exit intercooler to something along the lines of a tdr setup with the tubes exiting up. I know i could have probably got one already made that way, but I didnt consider this when buying this thing and didnt want to let it go to waste

cut the endtanks:


cut up some spare aluminum piping laying around in the garage to fit:


welded:


Its definitely not finished product, I have a lot of shaving/grinding/cleaning up to do on the welds, but its a start

more to follow as we actually start installing this thing.
-Vlad
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Old 01-28-2009, 01:20 AM   #2
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you and pat are my heroes
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Old 01-28-2009, 01:36 AM   #3
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Saweet! So how exactly will you be routing the piping? And are those overall dimensions or core specs? That's gonna fill the mouth out nicely.
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Old 01-28-2009, 01:39 AM   #4
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it should fit the mouth completely, which is why I chose this size in the first place.

I will be lowering the stock radiator/condenser as low as I can, slanting it as far back as possible (might need to buy slim fans for this), and the piping will go straight up and into the turbo/intake mani. we will weld as much as possible. I am hoping to have a total of 2 couplers on there. the less failure points and the straighter the routing the happier I am

*edit:
something along the lines of this but without the couplers:


actually here's a much better illustration:
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Old 01-28-2009, 01:49 AM   #5
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Actually, I'd settle for four couplers, two on the IC, one on the turbo, one on the TB. You don't want to make it all too rigid as the engine will torque when you hit overboost/shift/etc. If you make it too rigid, you'll just break ****. I did four couplers on mine as I described above. So far, no problems with pipes coming loose.
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Old 01-28-2009, 01:52 AM   #6
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Well in that case 4 couplers is still not bad
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Old 01-28-2009, 01:55 AM   #7
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Bead the pipes and T bolts. They work. I should have beaded my pipes. IE-weld a ring around them so the coupler won't slip off when the T-bolt is tight. I almost did it, the way my pipes are done, they can't really "pull" loose. IE-for me to take a pipe off, I have to unhook both ends or it's not happening.
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Old 01-28-2009, 03:33 AM   #8
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Looking good!! I'm debating on updating my setup and using a similar design, must keep A/C though.
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Old 01-28-2009, 09:58 AM   #9
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Aren't you worried about aluminum shavings from the cutting getting into the IC core? And from there into your engine?
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Old 01-28-2009, 04:45 PM   #10
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Quote:
Originally Posted by deliverator View Post
Aren't you worried about aluminum shavings from the cutting getting into the IC core? And from there into your engine?
Can be easily flushed out with a hose or in the bathtub.
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Old 01-28-2009, 04:54 PM   #11
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Yeah, I used a water hose and leaf blower to clean my IC. Cleans up easy. Just stick one end in the ground and fill it full of water, pick it up, and it all dumps quick, carrying any debris with it. Used a leaf blower to dry it out.
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Old 01-28-2009, 05:26 PM   #12
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Quote:
Originally Posted by zoomin View Post
Looking good!! I'm debating on updating my setup and using a similar design, must keep A/C though.

18psi; are you keeping the A/C?

I like the concept.
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Old 01-28-2009, 05:34 PM   #13
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i need a tig.
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Old 01-28-2009, 08:08 PM   #14
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I am running both a/c and power steering on my car and intend on keeping both. The aluminum shavings can easily be flushed out. I am going 1 step further: my uncle who I keep talking about, works for a big radiator/intercooler company for big ships airplanes, etc...He will hook this thing up to a pressure tester and see how much psi this thing can hold, as well as a flow bench (I think thats what its called) to see how much it will flow now that we've altered the end tanks. It should be fine but we'll check just in case.
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Old 01-30-2009, 01:34 AM   #15
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looks awesome i think i might have to do something similar on my vehicle.
any chance you will be making these available to the public?
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Old 01-30-2009, 01:52 AM   #16
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Its a possibility. LOL we are not a performance shop or anything, dont get the wrong idea
but if someone would be that interested than once I'm done I can see about replicating it. I'd use a different intercooler core if I was to do it again though.
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Old 01-30-2009, 10:24 AM   #17
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I think that's actually a huge improvement over the original inlet/outlet pipes. Too bad you've got that little bump at the base of the junction - but probably a lot more work to fix it. Could be addressed like this with a piece of tube, flattening out the end:
(then again that might be your plan since you haven't welded up that part)
Attached Thumbnails
The intercooler build begins -_--endtank.jpg  
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Old 01-30-2009, 11:51 AM   #18
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that is getting rather nitpicky, but you do have a point
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Old 01-30-2009, 12:07 PM   #19
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My biggest problem with that IC isn't the tanks. It's the size of the core itself. Needs to be taller or thicker. You're gonna loose a few PSI through that IC because of the pressure drop across it. Not ideal. If a 7.5 x 2.5 ain't much. Mine's 12x3, and I wish it was more.
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Old 01-30-2009, 02:58 PM   #20
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Quote:
Originally Posted by patsmx5 View Post
My biggest problem with that IC isn't the tanks. It's the size of the core itself. Needs to be taller or thicker. You're gonna loose a few PSI through that IC because of the pressure drop across it. Not ideal. If a 7.5 x 2.5 ain't much. Mine's 12x3, and I wish it was more.
Well I'll give this one a shot first. If you are right and the core ends up being too small I'll just get a bigger one off fleabay
They are cheap enough for me to experiment with, and the sizes available range from tiny to as big as my bumper lol
Quote:
Originally Posted by m2cupcar View Post
I think that's actually a huge improvement over the original inlet/outlet pipes. Too bad you've got that little bump at the base of the junction - but probably a lot more work to fix it. Could be addressed like this with a piece of tube, flattening out the end:
(then again that might be your plan since you haven't welded up that part)
That is an interesting idea. We did consider it actually. My dad was suggesting we make our own completely custom end tanks that would look pretty much like what you have drawn. After a bit of measuring we decided against it: its just not worth it. The core is way too small for that to be a "restriction" pretty much. I will see how this works out, if it proves to be too small like Pat says, we will try out a bigger core.
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