kenewagner
Registered User
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
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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