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Don B and others w/in CUSTOM intercooler fabrication

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Old Apr 20, 2002 | 12:35 PM
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Don B and others w/in CUSTOM intercooler fabrication

We are getting ready to start welding everything up this coming week.

Here is the core


And here is all of the parts imus one of the water ends tanks that is still being cut. JC93Z is helping out by cutting them for me.
We are welding 3/4" NPT aluminum couplings on for water in and out. 1 on each end.
Attached Thumbnails Don B and others w/in CUSTOM intercooler fabrication-intercooler4.jpg  
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Old Apr 20, 2002 | 03:02 PM
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From: NewCastle,DE USA !
By the looks of things, I am glad i bought mine from Spearco assembled. Then again, I don't have the resources that you do. Best of luck, make sure we get some pics of the final product!
BTW, I sold my Spearco, and have something else in the works
Later, Don B
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Old Apr 20, 2002 | 07:19 PM
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Guido,

Just out of interest, how much has/is all of this stuff costing you? It's not as if you're going out to a breakers yard and foraging for used bits, you're buying weapons grade material. And I like that in a man! :sillylol: :sillylol: :sillylol:

Robert
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Old Apr 22, 2002 | 12:05 AM
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I hope you dont like men Robert!! Im an exit only guy! hahaha

The core new from spearco is like $1040. I bought the core only from a friend in Indianapolis that is a spearco dealer. I paid $550 for the core. Ive also got $20 in sheete aluminum that is .095" thick. I drew up what I wanted the end tanks to look like in AutoCAD and then emailed the files to a friend of mine that works with a wire EDM cutting machine. He cut the shapes out for me. Im taking the plates in where I work this week and they are going to bend them the way I need to. The guy who welded up my headers for me is also going to weld these tanks onto the core which also needs some finishing work done to it.

Ive had a lot of great resources for this project that have helped me to save a LOT of $$. So that has been tremendous support for this project.
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Old Apr 22, 2002 | 08:34 AM
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From: NewCastle,DE USA !
Guido,
What core is that? It looks like the 2-170, but i may be mistaken. As you know, I had the 2-230 assembly. Will this assembly look similar to that? I was wondering that because it was a PITA to find an adequate mounting spot for that thing. And you have a lot more going on under the hood than I do.
Your buddy has acces to an EDM :hail: :hail: see, I knew you had more resources than me
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Old Apr 22, 2002 | 09:28 AM
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My assembly is a 230... it just arrived as a pair of 170 cores. I ordered it as a 230 and they said that they wouldnt weld them together WTF??

So they sent them to me like this and we are going to finish what they wouldnt do.

EDIT: It is going under the dash. I am having trouble seeing where it would go under the hood so a little more piping and its going under the hood. Ill just turn up the turbo a little bit more since I wont even be pushing it close to its limit.

Last edited by Guido; Apr 22, 2002 at 09:30 AM.
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Old Apr 22, 2002 | 09:31 AM
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Yeah I have access to an EDM machine. PLus the place I work at doesn't care if I use it for car parts or not, so that is really cool. If you went some where else to get this cut on a EDM machine, it would be about 60 an hour. These took about 5 hours to cut. But the cut quality and tolerance are exact.

Last edited by JC93Z; Apr 22, 2002 at 10:26 AM.
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Old Apr 22, 2002 | 04:25 PM
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Originally posted by Guido
I hope you dont like men Robert!! Im an exit only guy! hahaha
:sillylol: Fear not Guido, I'm not that kind of guy.

Have you thought about making a few sets of your headers up and selling them to any of us? I'm sure I'm not the only one who would be interested in them. What's that? You're going to wait and offer us a whole turbo kit for $1,500? Wow thanks Guido

Robert

Last edited by RMK; Apr 22, 2002 at 04:30 PM.
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Old Apr 22, 2002 | 04:38 PM
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lol @ Robert. The whole kit for $1500? lol that wouldnt even cover the cost of the turbo itself. lol

I have about $950 in the headers including materials and what I paid the guy to weld them up. About $600 in an intercooler, $1800 in the turbo, $500 in the wastegate.

And i still have to do all the intake plumbing, buy a blowoff valve, 4" exhaust tubing and hose couplings too. Still a little ways off yet but its coming together nicely now.
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Old Apr 22, 2002 | 10:26 PM
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shoulda just bought some banks manifolds and ran some big boost
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Old Apr 23, 2002 | 10:13 AM
  #11  
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Small update

We formed the pieces up this morning so I snapped a picture of everything sitting in place. Getting the other water end tank tonight and then all that needs down is to shear and roll some pieces for the inlet and outlet then weld it up.

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Old Apr 23, 2002 | 10:57 AM
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From: NewCastle,DE USA !
That thing looks great! :hail:
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Old Apr 23, 2002 | 06:58 PM
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Looks great Curt!! :hail:


Do you think you could make one yea tall, yea wide and yea long that fits under the hood of a Firebird and still flows 2000 cfm

I'm not asking for much am I?
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Old Apr 23, 2002 | 06:58 PM
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Diet and caffeine free coke, Guido? Watching your figure? LOL :sillylol:

That thing looks great. I can't wait to see it running. You have to get some video footate for us to salivate over.

It will all be worth it when it's finished. Tht's what I keep teling myself anyway

Robert
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Old Apr 23, 2002 | 07:22 PM
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Originally posted by RMK
Diet and caffeine free coke, Guido? Watching your figure? LOL :sillylol:

LOL! Have you seen his cage?? George..George..George of the jungle..
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