making a intercooler

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Posted · Report post

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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Posted · Report post

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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Posted · Report post

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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Posted · Report post

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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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Posted · Report post

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

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Posted · Report post

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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Posted · Report post

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

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Posted · Report post

NICE,, LIKE THE CLAMP IDEA,, LOOKS GOOD

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Posted · Report post

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":

P5180197.jpg

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Posted · Report post

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

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Posted · Report post

Nicely done how-to. Thanks

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Posted · Report post

I am bookmarking this one outstanding.

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Posted · Report post

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

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Posted (edited) · Report post

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

Edited by cherokeered

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Posted · Report post

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

I got it from Walmart . Homedepot also has it .

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Posted · Report post

that's awesome! thanks for sharing

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Posted (edited) · Report post

im glad you guy like the tutorial .

Edited by jdmfan

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Posted · Report post

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!

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Posted · Report post

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":

P5180197.jpg

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

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Posted · Report post

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

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Posted · Report post

Nice tutorial, thanks!

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Posted · Report post

here is a pic of my almost finished intercooler i build following this tutorial. it still needs to be blackwashed. I sprayed it with a Chrome finish Krylon spray paint. the "CHROME in a can" spray paint did a better job than i though it would!

this pic does not do the chrome spray paint any justice.

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and another one I made.

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looks better than without, don't you think?

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Posted · Report post

That does look great . I used to steel them out of my jada dicast till I realized that yo can do much better yourself.

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Posted · Report post

This is a great how to, I am going to try this out

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Posted · Report post

Who makes the SRT-4 kit? I had a 2004 Red 1:1...miss that car! I would love to do a model of it....

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