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making a intercooler


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#1 jdmfan

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Posted 03 April 2012 - 07:31 AM

a couple members asked if i could do a tutorial on how to make my intercoolers.

these are the tools and materials i use knife ,cutters, needle nose tweesers, styrene (2 different types 1 is metal siding .040 spacing and the other is just regular flat styrene) bondo ,red spot putty, tamiya 2 part epoxy putty, solder, aluminum tubing ,beading wire ,crazy glue sand paper and a ruler

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first thing i do is cut the metal siding to the size you want the fmic core to be( cut 4 pieces)

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glue the 4 pieces together and cut a small strip of the flat styrene the cut it into 4 pieces (there for the end tanks) and 2 pieces of solder for the inlets

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then i use the crazy glue to put the one side of the end tanks on and the solder for the inlets

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the using the knife i cut the the one side of the end tanks to the size and shape i want

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#2 jdmfan

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Posted 03 April 2012 - 07:37 AM

then repeat the same thing to the other size

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the mix the bondo up and fill in the end tanks

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then sand the bondo smooth and use the red spot putty to fill any pits

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the sand the spot putty after it drys

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#3 jdmfan

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Posted 03 April 2012 - 07:47 AM

then mix up a small amount of the 2 part epoxy putty

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then roll it into a small little line

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then put the little strips on the joints of the end tanks

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i use a small paint brush to push it down and make it strait across the joint . u might have to use the knife to clean up the epoxy to make the joint the size you require

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the using the knife i lightly make small pits in the epoxy to make it look like it welded
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#4 jdmfan

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Posted 03 April 2012 - 07:54 AM

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cut the aluminum tube for the end tanks

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paint the intercooler and end tanks i paint mine silver chrome and the aluminum tube black

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glue the aluminum tube on the end tanks over the solder

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i use tin tape to make the hose clamps

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the cut 4 small pieces of beading wire for the hose clamps

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#5 John Pol

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Posted 03 April 2012 - 07:55 AM

Real nice how to thats what we need on this site more how toos. How about guys want to share some of your knowledge with the rest of group.

John Pol

#6 jdmfan

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Posted 03 April 2012 - 07:59 AM

then i use flat black paint to make the intercooler pop out

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i just use my finger to to wipe the paint off leaving the grooves painted black

then you have your self a nice looking intercooler

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#7 Mike Kucaba

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Posted 03 April 2012 - 08:07 AM

This was worth it just for the tip on hose clamps!! Well done :D

#8 rel14

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Posted 03 April 2012 - 08:24 AM

NICE,, LIKE THE CLAMP IDEA,, LOOKS GOOD

#9 Bastardo

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Posted 03 April 2012 - 10:27 PM

Luv it :D

The way I did it once:
I made a plastic frame, painted it black, glued some soldering wire in it, made a frame out of an old 1.44 MB disk and inserted a piece of some fine mesh I got from who-knows-where-from:
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I scratch-built a fan and added it to the cooler:
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The final result after some wires and some "dirt":
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#10 allparish12

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Posted 04 April 2012 - 02:41 AM

VERY NICE tut!!!...i agree...we need more how to's...there are many ways to skin a cat

#11 cobraman

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Posted 04 April 2012 - 04:10 AM

Nicely done how-to. Thanks

#12 MicroNitro

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Posted 04 April 2012 - 04:13 AM

I am bookmarking this one outstanding.

#13 Steven Zimmerman

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Posted 04 April 2012 - 04:26 AM

GREAT tutorial, all the way through ! Well photographed, well explained....

#14 cherokeered

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Posted 04 April 2012 - 06:45 AM

Where did you get the Tin Tape?....Awesome Tutorial!!!

Edited by cherokeered, 04 April 2012 - 06:51 AM.


#15 jdmfan

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Posted 04 April 2012 - 09:02 AM

Where did you get the Tin Tape?....Awesome Tutorial!!!

I got it from Walmart . Homedepot also has it .

#16 dig

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Posted 04 April 2012 - 07:19 PM

that's awesome! thanks for sharing

#17 jdmfan

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Posted 04 April 2012 - 09:56 PM

im glad you guy like the tutorial .

Edited by jdmfan, 10 April 2012 - 07:14 PM.


#18 wraith

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Posted 10 April 2012 - 04:58 AM

I have built a couple intercoolers the 1st way described and with some blackwash you can get them looking very good!
I hope to have one of those builds done and posted soon!

#19 Romell R

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Posted 10 April 2012 - 05:12 AM

Luv it :D

The way I did it once:
I made a plastic frame, painted it black, glued some soldering wire in it, made a frame out of an old 1.44 MB disk and inserted a piece of some fine mesh I got from who-knows-where-from:




I scratch-built a fan and added it to the cooler:




The final result after some wires and some "dirt":
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Thats not an intercooler it's a radiator. but all in all it's a job well done. next time make a post of your own some may consider this thread highjacking

#20 allparish12

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Posted 10 April 2012 - 06:20 AM

did you widen the fenders yourself or was that apart of the kit? I've been looking for a bodykit/fender widening tutorial for a while...i've seen a couple of ones that suggest cutting the body, but i was looking for one that just adds styrene and some putty to sand down