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Thread: Diy intercooler

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    Roll Tide!! SeadooTech's Avatar
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    Diy intercooler

    Does anyone know where to buy the intercooler inlet and oulet tanks? I have a Chinese cooler that I can cut them off of but would like to buy them and use this cooler for another project....


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    If you can cut off a set of tanks, then you can easily fabricate them...Its just some flat sheet stock and an outlet, relatively easy to make

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    Roll Tide!! SeadooTech's Avatar
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    Sorry, yeah I can make the end tanks but not the inlet and outlet air tanks(not sure what they are called) I bought a 3" x1' round aluminum to connect the hoses to but the actual tanks are rounded..... will aluminum bend like steel when its heated up? Guess I can use a 4" piece of pipe to bend the aluminum around it for part of the air inlet/outlet

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    twokexlv6coupe's Avatar
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    Aluminum is one of the easiest metals to machine. EXTREMELY malleable (bend-able/form-able), doesn't need cutting fluid, can take some of the heaviest depths of cut, it just needs to be TIG welded.

    Yea if the core is 4" thick, I'd build a jig to be able to bend it 180* around a 4" pipe, cut to length/width, cut two end-caps, one with a 3" hole (assuming 3" in/outlets), TIG it together. Repeat x2.

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    Roll Tide!! SeadooTech's Avatar
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    Do i need to heat the aluminum to bend it around the pipe so it doesnt crack?

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    JFizzleJR's Avatar
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    Quote Originally Posted by SeadooTech View Post
    Do i need to heat the aluminum to bend it around the pipe so it doesnt crack?
    Make sure you get a grade that has good malleability or else it will start to crack no matter how you do it

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    Roll Tide!! SeadooTech's Avatar
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    Ok
    Last edited by SeadooTech; 01-25-2014 at 10:08 PM.

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    Roll Tide!! SeadooTech's Avatar
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    Quote Originally Posted by JFizzleJR View Post
    Quote Originally Posted by SeadooTech View Post
    Do i need to heat the aluminum to bend it around the pipe so it doesnt crack?
    Make sure you get a grade that has good malleability or else it will start to crack no matter how you do it
    Thanks fizzle, What grade would u prefer?

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    JFizzleJR's Avatar
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    5052 is pretty flexible

    Quote Originally Posted by SeadooTech View Post
    Quote Originally Posted by JFizzleJR View Post
    Quote Originally Posted by SeadooTech View Post
    Do i need to heat the aluminum to bend it around the pipe so it doesnt crack?
    Make sure you get a grade that has good malleability or else it will start to crack no matter how you do it
    Thanks fizzle, What grade would u prefer?

  10. #10
    Roll Tide!! SeadooTech's Avatar
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    Quote Originally Posted by JFizzleJR View Post
    5052 is pretty flexible
    OK do u think 1/16" is thick enough

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