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Thread: Steps to build a Double Intercooler

  1. #1
    Join Date
    May 2003
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    Omaha, Nebraska
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    Steps to build a Double Intercooler

    Posted pictures and information on how a Double Intercooler can be built. I have read many threads on Dbl ICs and decided to post pictures of the building of an Intercooler that was just built for a club member. Please do not post requests to purchase or price ICs in this thread, it is for information only.

    I strip all cores of powder coating. It makes welding easier and also cleans oil out of the pores of the alum making for a cleaner weld. Any plating shop will have a cold dip tank and will charge you 15 to 20 bucks. It is worth it

    On one core I cut both end tanks clear off since I do not use the stock end tanks. I feel they lack the size and shape to flow air well especially with the new blowers putting out more boost. After cutting off the end tanks as per the pictures I weld the two cores together as shown. I build end tanks out of 3/16" plate alum. I have patterns that I can trace on the alum and either shear or cut with a band saw. I install a 1/8" thick divider to split the air to allow even flow of air to both cores. The shape of the end tanks are what I like but can be done anyway a guy would decide to do his own. I tig weld all the joints using a 5356 tig rod. The inside of the top end tank is Mig welded to add strenth because I sand down the crown of the outside weld to produce a good looking end tank that looks more factory. After welding I pressure test all joints and the tubes as per pictures. You can see how the tubes leak and require sealing with epoxy. I finish the IC with an epoxy primer and 2 coats of a high gloss industrial urthane paint. I install side panels of polished SS with short SS screws.

    Some guys looking to build a dbl Ic of their own can use these pictures to build the best Ic they can. There is no patent on building IC so if you got the tools and abilties then it can be fairly easy. If not there are many talented guys in the club who can do them. I hope some of the pictures will help to show where the Ic leaks and how they are constructed. Ask the guy who builds your IC if he reseals it, does he pressure test it. If not your car will have a vacuum leak that will drive your idle crazy. A double IC is a good mod if a FMIC is not in the price range or plans and built right will far exceed the stock single IC from the factory.

    Ken
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    Last edited by kenewagner; 06-10-2007 at 02:17 PM.

  2. #2
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    May 2003
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    More pictures
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  3. #3
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    May 2003
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    Last of the pictures
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  4. #4
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    Apr 2002
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    Lakeville, MN
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    Nice work and thanks for sharing the info.

  5. #5
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    Jul 2004
    Location
    Chicago, Il
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    AWESOME!!! I'm hoping to get one soon!

  6. #6
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    Jul 2003
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    Orlando, Florida
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    Thanks for the post and pics. I will be tossing the one I started and start a new one. Nice Work....

  7. #7
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    Apr 2002
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    Thorold, Ontario, Canada
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    did you paint or powdercoat the IC when you were finished? I plan on powdercoating mine so I think I will powdercoat it first then reseal the entanks afterwards. How hot can that epoxy handle? I was worried powdercoating it would possibly crack it again so thast why I figure I'll coat it first.

    Nevermind I just missed where you said you painted it, DOH!

  8. #8
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    Oct 2005
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    oregon
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    461

    got the materials to do this /couple questions.

    after IM done I want to re rout my inter cooler tubes Ive been searching posts havent found anything. whats a good way to re rout. also Im going with the 3" alum, tubes I see no way to connect with out cutting my stock ones to leave couple " to have something to use the blue rubber couplers on is that how its done? thanks

  9. #9
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    Quote Originally Posted by shawpdx1 View Post
    after IM done I want to re rout my inter cooler tubes Ive been searching posts havent found anything. whats a good way to re rout. also Im going with the 3" alum, tubes I see no way to connect with out cutting my stock ones to leave couple " to have something to use the blue rubber couplers on is that how its done? thanks
    3" is over kill and you will find it harder to find the room to install the bigger tubeing. Not saying it cant be done just harder. If you havent scaled everything else up to match it is a waste of time. The lower intake manifold inlet would neck it down unless it was opened up to match. 3" looks nice on some pictures I have seen but in reality a waste. There are many diffrent ways I have seen to run new IC tubes if you have a FMIC. I have not explored any other ways with a stock or double IC as I dont have either. The Dbl IC could have the stock hookup deleted and a nipple welded in place. You would have to fit the tubeing to make it work from there. Relocating the battery to the trunk makes a little more room to run tubes. I ran my side by side which worked for me but not for everyone else. The picture is an old picture of my car with the M90 but the IC pipes have remained the same.

    Ken
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  10. #10
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    Aug 2003
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    Thumbs up

    That car is a real work of art. Excellent work on the intercooler. Do you have a site with other pics of your car?

  11. #11
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    Jul 2004
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    Hamilton NJ
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    Very Helpful

    It's very good information for someone wanting to try and make one on their own!!!!!

    Don't mean to get off topic but did you make the brake res. covers for the 89-93 years yet? If you had posted before that you did Sorry I didn't see it.

    Tom
    Tom Downs-member#2752
    MPX'd 90 SC Auto~bought Feb. 2012
    RIP MOM!!! I will always miss and think about you 4Ever! 1940-2018
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    http://www.sccoa.com/forums/garage_v...vehicle&id=424

  12. #12
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    Quote Originally Posted by 89XR7TD View Post
    It's very good information for someone wanting to try and make one on their own!!!!!

    Don't mean to get off topic but did you make the brake res. covers for the 89-93 years yet? If you had posted before that you did Sorry I didn't see it.

    Tom
    One of the local members gave me the older resivors. I havent had time to fabricate a cover for it yet. Trying to put my car back together and its always fighting me from making it beautiful

    Ken

  13. #13
    Join Date
    Sep 2002
    Location
    SE CT
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    740

    What shield gas did you use?

    Kenewager, what gas and settings did you use when doing the MIG'n & TIG'n?
    Fixing to start on raising my top and turning the in/outlets on my fmic. My TIG rig has HF and Pulse, MIG dosen't have a spool gun yet.
    If you could recall the settings and PM me I would appreciate it.

    Thanks MikeH

  14. #14
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    Jan 2003
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    Columbia, SC
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    I wonder if the "splitter" you install actually does anything? I would think that the air would follow the path of least resistance and naturally distribute itself as required to get the same pressure drop across all of the core passages.
    22 year SC Owner GFP
    (Glutton for Punishment)
    1992 5 Speed SC one of 1256
    1995 5 Speed SC one of 574

  15. #15
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    Dec 2007
    Location
    Salem OR
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    The 'path of least resistance' would seem to be the near core, which would presumably be prone to running a lower temperature and higher flow...different from the far core. I'm not sure pressure differential across cores/passages would be a factor.

    Without a diffuser coaxing a certain percentage of airflow beyond the primary/near core, the far core would perhaps risk being deprived.

    Which electric fan is that?
    Last edited by KMT; 08-13-2008 at 12:27 AM.

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