Author Topic: home built intercooler? (Read 3182 times)

haybayian · « **on:** November 23, 2007, 05:31:46 am »

I am trying to grapple with the issue of intercoolers. They seem too bloody expensive for what they are. My AAZ will run twice the intake pressure of a TDI. I figure that stock or aftermarket AKG TDI intercoolers ($200)may not be rated to that kind of pressure. Then racing product suppliers sell their intercoolers between 800$ and $2000. My question to you wisemen is this. Can we make one?
How? Did anyone have any success?

Haybayian.

jimfoo · « **Reply #1 on:** November 23, 2007, 06:12:45 am »

E-bay or junkyards, as they are way cheaper than new. Although I bet you could make one, I highly doubt it would be worth the time and effort, and wouldn't be nearly as efficient as a pre-made one.

RabbitGTDguy · « **Reply #2 on:** November 23, 2007, 09:34:32 am »

Ebay and the jyard are indeed the best place...

Best in OEM to look for... hmm...there are a number of good ones. The SAAB blackstone all aluminum version (there is a plastic tank version) is good, Starion intercooler is nice, Ford Probe GT unit...not bad...

Also, any number of intercoolers out there with plastic tanks can have those tanks removed and aluminum ones fabbed welded on... if your handy with the fabbing and welding skills there.

Also, spearco cores and other cores are available all the time for VERY decent prices on ebay and are very nice flowing cores...the endtanks for those have to be fabbed and welded on as well.

I've seen several guys take and run dual G60 intercoolers with custom endtanks (but fit OEM bracket mounts) on their setups (gas and diesel) as well as TDI cores, audi 5k cores (there was a guy on the net making stock 5k intercoolers into aluminum end tank units and reselling...don't know if he is still around).
Lots of options....time and money are the question

Corky Bell's book "Maximum Boost" has some do's and don't' s for intercooler end tank flow/design as well as core construction for max flow and efficiency if you want to do some reading

Joe

jtanguay · « **Reply #3 on:** November 23, 2007, 12:27:23 pm »

http://cgi.ebay.com/ebaymotors/Universal-Intercooler-18-Lx12-Hx3-W-ECLIPSE-PRELUD-Saab_W0QQcmdZViewItemQQcategoryZ33742QQihZ019QQitemZ290183831557#ebayphotohosting

around $70 after shipping. pretty big size, all aluminum easily capable of handling 20 psi all day long

dont forget to make sure that all your other connections are capable of sustaining 20 psi boost though. (make sure to have beads on all connections so the hose clamp has something to bite into when being yanked on.

haybayian · « **Reply #4 on:** November 23, 2007, 02:09:18 pm »

Quote from: "jtanguay"

http://cgi.ebay.com/ebaymotors/Universal-Intercooler-18-Lx12-Hx3-W-ECLIPSE-PRELUD-Saab_W0QQcmdZViewItemQQcategoryZ33742QQihZ019QQitemZ290183831557#ebayphotohosting

around $70 after shipping. pretty big size, all aluminum easily capable of handling 20 psi all day long

dont forget to make sure that all your other connections are capable of sustaining 20 psi boost though. (make sure to have beads on all connections so the hose clamp has something to bite into when being yanked on.

Thank you Guys for your guidance.
Yes fabricating does not seem to be worth the trouble. E-bay if you have Paypal, Autoparts Online Canada if you don't, That's it.
Haybayian