got an idea...I could just fab brackets to go around the inlet/outlets or over the pipes couldn't I?

Here are some pics of that damn intercooler.

http://i84.photobucket.com/albums/k2...Picture009.jpg
http://i84.photobucket.com/albums/k2...Picture007.jpg
http://i84.photobucket.com/albums/k2...Picture010.jpg
http://i84.photobucket.com/albums/k2...Picture013.jpg
http://i84.photobucket.com/albums/k2...Picture012.jpg



Its kinda beat up, so I don't know if I could sell it for much, which is why I was wondering if I could use it in the begining :D

3.5" is thicker than mine. I don't think it's a problem that it's that thick... but you still have the small pain of welding to aluminum...
Nothing wrong with that IC at all that I can think of. Looks almost identical to mine within and inch or so.

I say use it

I was thinking about making brackets to go around the inlet and the outlet maybe after the pipes are clamped on...see if I can fab an idea up.


The damaged fins wont hurt as long as the plate thingys (tubes? lol) are not damaged right...or the endtanks?

Right.

If you do try to sell it, pressure test it and include that info. One would feel better about buying a used intercooler should these steps be taken and documented.

I say if it fits, use it.

How can I pressure test it? or do I need to have someone do that?

Make a "pressure tester." I made one, I have to find it if you want a pic, but cheap materials and a coupler plus an air tank is all you need.

Basically I found a piece of PVC pipe that is the same size as your i/c inlet/outlet and put a PVC "cap" on the end. Sealed of course. Then, attach a coupler on one side to seal that side off. On the other side, duplicate the PVC setup, but drill a hole and insert a valve stem to attach an air tank hose to. Put 20 or so psi in your tank and connect the hose to your contraption. See if it leaks.

go to like ace hardware in the plumb section, you should be able to find a 2" rubber cap. They also sell stem valves, i think in the brass fitting section, I know they have them somewhere. So then just drill a tiny hole in the middle of the on rubber cap, shove the stem valve threw. Clamp both on and run a bike pump into it.

hehe...I've got a lowes hardware up here, might have to deal with that until I go back home.
Will a bike pump move air fast enough to see if I have a leak...and whats the best way to find one if its small...kinda like a tire? soapy water trick?

hey samnavy can you post a few pics? I'd like to see your setup?

I think if you just cap it and pump it up with air like a tire you should either hold pressure or loose pressure. I have a pump with a gauge and it worked good for testing my IC.

I did 10 psi

well it gets pressurized like a tire. youll see how much it can take, pump it to like 10-20psi and let it sit.

Sometimes I don't think about stuff before I post...actually that happens a lot.

Should it stay full for a while...or is there a reasonable limit on it leaking?

you basically want to see if it can hold for a while, that way you know you won't lose boost.

Sorry, no pics yet. The UPS tracking number says the turbo gets here tomorrow. The downpipe shipped early last week from Begi... expect it any day! YEAH!
The best I can do is the paint diagram I attached in POST #15 on page 1 of this thread. I've also got some more IC stuff going on in another thread here: NO HIJACK INTENDED:
https://www.miataturbo.net/forums/showthread.php?t=4966

If it all goes according to plan, just two 45* pipe sections and three pieces of silicone on the hot side, and three pipe sections (one 45* and two short straights) with two 3 90* couplers and a 2-2.5 reducer on the cold side. OR SOMETHING LIKE WHAT I JUST WROTE. I WON'T MAKE A FIRM DECISION UNTIL IT'S ALL IN PLACE AND I'VE MOCKED UP THE PIPES WITH PVC THAT I'VE BOUGHT.
You guys will be the first to see pics when this thing happens. I've got no "Miata related" secrets from y'all. Two F150 Supercrews just popped up today at Cars.com here in VaBch. I have to remember to bring a change of civvies tomorrow so I can go look after work.

which ebay company did you use? I am thinking about doing this for my greddy kit but I dont know what bends I need. Anyone know?
I was thinking about buying this IC from ebay
http://cgi.ebay.com/ebaymotors/18x12...QQcmdZViewItem
and then getting one of the ebay companies to send me the pipes I need

The one in the link a couple posts above where you quoted from. They wrote back with a quote of over $160 dollars and that didn't include T-clamps or he 90*reducer. I may end up sourcing parts from a couple places. Also, the DSM compressor housing has a 1.75" inlet from the MAF... so I'll need to go from the 3" MAF to that via coupler... more $$$. I'm just gonna wait until it's all in, then mock it up, then buy what's cheapest.

I've really been all over the place with my decision on what to buy. I've dropped the ball on IC stuff to concentrate on just getting a good turbo... for now. But my UPS says my DP arrives on Monday, 2 more turbos this week... then a new truck to drive, then assemble, then IC.

sheesh. whats with 2 more turbos?