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Changing intercooler plastic end tanks?
by
RunninWild
on 30 Oct, 2016 18:09
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I just bought a jetta 1.8t intercooler to try and fit into my samurai. Its a perfect fit other then the one end tank. There is no way for me to mount it without having a hose come out of my grill and loop around and then back in the engine bay. Has anyone successfully ever changed the end tanks? I'm thinking of buying a second intercooler and taking the end tank off and putting it on mine. I'm assuming its as simple as bending the tabs around the tank back and gently prying it off, then cleaning everything good and putting the tank onto the other cooler and bending the tabs back into position? Maybe a bit of silicon sealant around the edge for a bit of insurance?
Basically want the tank on the right to be on both sides.
After doing a bit more research I should have just got an a4 intercooler which has the proper end tanks
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#1
by
RunninWild
on 30 Oct, 2016 21:06
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well I had a go at plastic welding lol. I'm kind of surprised it turned out half decent. Think it would hold pressure if I jb welded both sides? As of right now it holds water without leaking... Anyone have a good way to pressure test the intercooler when I put it all back together? ideally looking for it to hold 25psi.
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#2
by
fatmobile
on 31 Oct, 2016 12:28
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You know they have special glue that's just for that plastic right?
So you didn't pull the end cap off? I was wondering if that would work.
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#3
by
RunninWild
on 31 Oct, 2016 16:35
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I did pull the ends off. There was some oily gritt inside the end tanks so I pulled and cleaned them.
If you are talking about that plastic weld glue, I've used it in the past and its pretty crap tastic
I had a bottle of gorilla glue sitting in my drawer and decided to see how well it works. Covered the outside of the tank in it, I think I'm going to jb weld the inside seam as its easier to smooth out and doesnt expand like gorilla glue.
I'm going to get a bike tire tube and use some rubber to close off one of the inlets, the other one I'm going to use the schrader valve and pump it up and see if it holds pressure. If it holds 40psi submerged under water I'm going to call it good and run it
I just coated the inside with jb weld plastic weld putty. Says its good for 350psi. I've never used this stuff before. Sticks to my fingers more then the plastic but we'll see how it is when it cures. I'll put it all back together tomorrow and test it for leaks.
Well its back together. Gorilla glue didnt bond to the plastic so I put the plastic weld on both sides. My bike tube idea isnt going to work as I cant stretch it enough to be able to clamp it on the inlets. Think I might try some pvc caps and silicone the schrader valve from the bike tube onto one of the caps
I didnt originally plan on making my own end tank. I was just of just messing around but I'm surprised how well its turned out. If it passes a pressure test I'm just going to run it.
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#4
by
RabbitJockey
on 01 Nov, 2016 06:07
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i think it will blow apart... but its always worth a shot i guess. if you could get another one you could just swap so both endtanks are the same
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#5
by
RunninWild
on 01 Nov, 2016 15:33
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Yeah jb plastic weld doesnt hold pressure at all lol. Gonna just grab another end tank from the wreckers.
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#6
by
libbydiesel
on 01 Nov, 2016 18:02
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#7
by
RunninWild
on 01 Nov, 2016 19:52
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Well I got it for $20 and I thought I could make it fit. after shipping and exchange that one would cost about $90. A end tank will probably cost me $10. I'm pretty confident I can get the end tanks to seal.
Student budget, if I had the money I probably would have just went an awic...
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#8
by
fatmobile
on 08 Nov, 2016 13:47
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Not just regular plastic epoxy,.. there is some special stuff just for the radiator plastic.
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#9
by
libbydiesel
on 08 Nov, 2016 16:27
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Ok, $45 or $90, that's minuscule compared to the cost that could result from overspeeding the turbo when tank blows up or bending a valve/rod when a chunk of your glue gets sucked into the engine. Even the cost of sitting at the side of the road waiting for the tow truck, or running it and sucking unfiltered air into your engine when you limp home with no boost. It all seems penny wise a pound foolish to me.
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#10
by
RunninWild
on 08 Nov, 2016 16:33
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Like I said I was doing it for more of an experiment and killing some time more then anything. Wasn't originally intending to run it when I started playing with it. Its over with now. Use it as a guide on how not to repair plastic end tanks or just delete the thread...
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#11
by
Toby
on 11 Nov, 2016 07:46
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FWIW radiator shops have the equipment to remove and replace those tanks. When you find a tank that works you could have them install it and pressure test it to boot.
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#12
by
regcheeseman
on 11 Nov, 2016 15:20
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Yes you can swap end tanks, exactly as you suggest, bend back the tabs and fit the new end with a sealant - I've used tiger seal/sikaflex/rhino seal in the past.
Though buying a suitable alloy intercooler may provide a better solution.
