DIY Intercooler
Turn's out making the intercooler was the easy bit, pipe work is much more fun!
Firstly I bent back the aluminium tabs holding the plastic caps in place and removed them.
Then I cut the top and bottom end caps in half so that I could re-joint them with only 1 inlet in each, i've used liquid metal to stick the 2 half's back together. I had to do a bit of sanding to flatten the caps so that they fitted back onto the intercoolers, then using a pair of grips and a hammer knocked the tabs back around the caps.
To join the intercoolers I bent the tabs back in on themselves on one end of each intercooler then lined the two up so that the passages were in line and with no gap. The using aluminium mig wire and argon gas shield I welded the 2 together using the tabs as they all lined up, then the gaps have been filled in.
To finish it off I'll either use Fibre Glass resin or Liquid Metal around the end caps and the centre section which should seal it up/reinforce it.
Before using it I'm going to try and test it using a pressure brake bleed kit and a spare tyre set to about 15-20psi.
The problem with welding aluminium is it tends to produce alot of loose bits so i had to be carefull not to get any stuck between the weld and the passages, i did'nt want bits being drawn into the engine so i just welded it so it was solid,then filled the gaps, it also gave me an opportunity to shake out any loose bits after welding.
If it works I'll prob replace it with something like this
http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=7977531210&rd=1&sspagename=STRK%3AMEWA%3AIT&rd=1
and get new piping made up for it, i should be able to find a local company that can suppy/bend it to the right shape.
I was planning on a head light conversion anyway so it kinda fit's in with what i've got in mind.
PS - suffering from insomnia at the mo so that's why i'm posting @ 2am!!!!!