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Old 11-24-2009, 01:30 AM   #1
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Can you cut an intercooler core in half, mine is too long and I don't want to buy a new core...is this possible??
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Old 11-24-2009, 01:37 AM   #2
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you can cut it in half. But how will you put an end tank back on there? They are not just "welded on" btw
Unless you work for a rad/ic shop I don't see it possible to do that.
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Old 11-24-2009, 01:39 AM   #3
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My end tanks are welded on....

Isn't that the point of buying cores so you can weld your own end-tanks on? Have any idea what to cut it with?
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Old 11-24-2009, 01:42 AM   #4
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Probably more worth your time to buy a new one. You'd have to cut the end tank off, cut the core to size, deburr the entire core and end tank, as you don't want any of the shavings in your engine (and there will be A LOT of shavings), then have it TIG welded back on, and pressure tested for leaks. The welding and testing will probably be around $100 from a reputable shop, and the cutting and deburring will be about 3-4 hours I'd say. Worth it?
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Old 11-24-2009, 01:45 AM   #5
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True, thanks a lot for the info.
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Old 11-24-2009, 01:48 AM   #6
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Those little plates on the ends of the core are pressed on and some sort of glue material is used. Then they go into an oven for a long time. Then the tanks are welded on.

Its definitely not worth the time/effort to do this, especially since other sizes are so cheap these days.

My dad used to work for JB radiator co.
The process their intercoolers went through to ensure quality and reliability was insane. One little flaw and they'd just trash the whole core.
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Old 11-24-2009, 01:52 AM   #7
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umm i wouldnt that is alot of welding to do.,
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Old 11-24-2009, 02:17 AM   #8
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Sell and buy! No need to put that much labor in.
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Old 11-24-2009, 03:23 AM   #9
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...why the **** would you weld an end tank back on there? That takes away from the cold air it could suck up.
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Old 11-24-2009, 01:09 PM   #10
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I decided to just cut up the front end, and remove the crash bar etc to make it fit...
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Old 11-24-2009, 04:14 PM   #11
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That works
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