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making a intercooler


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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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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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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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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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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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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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  • 3 weeks later...

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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