yeay..fun time with intercooler piping, 3sgte intercooler piping fabrication pics Options

[presure2]

this is my "fun" time.
fabricating intercooler piping.
somehow, i find it relaxing.

this is supershannons 3s equipped ST (formally RJB's)
im fixing the hack job that was called a swap, including the intercooler piping, and a bunch of other stuff that needed to be taken care of.
all 2.5" stainless, welded with 1 joint for a bit of flexibility on the hot side, and 1 joint on the cold side.
here are a couple pics.



once the welding is all done, i'll prep the welds a bit more, and prep the whole pipe, so that they will be ready to polish if they choose to do so.
you can see in the pics the start of preping the welds, the first weld off the turbo is just ground down with a angle grinder, the 2nd by the alternator has been ground with the grinder, then prepped a bit with a roloc disk

no, im not clocking the turbo.
IMO, unless you have an IC with the inlet and outlet on the same side, you gain nothing by doing it.

more pics to come

[x_itchy_b_x]

Manny, you never stop do you? Thats great. That looks like big pipe in the pictures!

[presure2]

Manny, you never stop do you? Thats great. That looks like big pipe in the pictures!

hhaha, you know, man...theres always something going on..lol
i was tempted to call you when i did the tbelt, first time doing a 3s belt in the car...
wasnt as bad as i was thinking it was gonna be.
reinstalling the turbo setup sucked more...that damn feed line bolt was a pain!!

it does look big in the pics..its juts 2.5"..ill also be making them a 3" stainless intake as well.

[stetsonaw]

looks good man. nice job, can't wait to see more pics.

[easternpiro1]

you are the man manny!

[Punisher]

Ahh.. that's why I prefer to TIG weld my pipes.. Nice beautiful welds no need to grind them down.

[presure2]

Ahh.. that's why I prefer to TIG weld my pipes.. Nice beautiful welds no need to grind them down.

meh, cant afford/dont know how to tig, although they do look damn good when done right.

thanks guys.

[Punisher]

Ahh.. that's why I prefer to TIG weld my pipes.. Nice beautiful welds no need to grind them down.

meh, cant afford/dont know how to tig, although they do look damn good when done right.

thanks guys.

Well I have a friend who owns a machine shop

I would put my pipe together here using my little lincoln mig welder using stainless wire.. either fully weld them or just tack and then go down to the machine shop and finish welding with the tig or just use the tig to go over the welds to smooth them out.. my mig welder didn't have enough current to get the stainless hot enough.. so I'd always end up with little leaks and ****ty looking welds with it.

What are you using welding wise, what welder.. type of wire and gas? oh and what type of stainless?

This post has been edited by Punisher: Dec 25, 2007 - 9:09 PM

[presure2]

Ahh.. that's why I prefer to TIG weld my pipes.. Nice beautiful welds no need to grind them down.

meh, cant afford/dont know how to tig, although they do look damn good when done right.

thanks guys.

Well I have a friend who owns a machine shop

I would put my pipe together here using my little lincoln mig welder using stainless wire.. either fully weld them or just tack and then go down to the machine shop and finish welding with the tig or just use the tig to go over the welds to smooth them out.. my mig welder didn't have enough current to get the stainless hot enough.. so I'd always end up with little leaks and ****ty looking welds with it.

What are you using welding wise, what welder.. type of wire and gas? oh and what type of stainless?

its just a little lincon 135T..nothing special..409stainless for the IC piping..i figured no need for 304 for intercooler piping, where it will never see road salt or anything like that..if it were an exhaust, i would prefer to use 304, but for this the 409 will be just fine...
i wish i had a machine shop on hand..although, i must say. my local guy has been pretty cool with me.
im having fun, and learning in the process. thats the important thing for me. im by no means a professional, i just like doing this crap in what little spare time i have.

good to see you active and making good posts man.

[Punisher]

haha My MIG welder was a lincoln 135SP Plus!

304 is expensive.. like 16 dollars a foot.
That 409 will still rust on you.. and be sure if you use any type of wire wheel on it that it is a stainless wire wheel.

[presure2]

haha My MIG welder was a lincoln 135SP Plus!

304 is expensive.. like 16 dollars a foot.
That 409 will still rust on you.. and be sure if you use any type of wire wheel on it that it is a stainless wire wheel.

all the prep on the pipes are done with fresh roloc disks, and prep pads
im not worried about rust on these pipes at all.
i've had my IC piping for 2.5+ yrs, aluminized steel, and no rust, with the open gt-4 hood and all..once you install the underbody plastics, with a stock hood, theres no issues to worry about there.
just need to fab up a couple brackets for the IC, then ill finish up the ic pipe, and make the intake as well.

[presure2]

so, i fabbed up the intercooler brackets, and got the intercooler mounted, and some of the cold pipe made up, i made up a couple bolts out of the threaded rod and bolts RJB used to mount the intercooler to the crash bar before, the intercooler was pushed way out to the front of the crash bar, and he had to cut away parts of the bumper to fit it over the IC and piping.

a pic of the bolt:



the bracket welded to the frame ( i cleaned and painted these, this stuff will rust pretty quickly without protection)



the IC mounted:



yup, i think the brackets will hold just FINE....


haha yes, that is me, STANDING on the intercooler.

[jcbass7]

haha, nice work manny, keep it coming!

[Batman722]

I thought you'de be doing that last night

looking good man, I might swing by tonight.

[presure2]

finished up the fabrication of the pipes today.
just waiting on the BOV flange to arrive, and a few couplers, and ill finish up preping the pipes, and it will be all done.

[supershannon77]

Manny nice work...i just saw the post now...I love you man thanks for all the help u have giving me!!!!

[goferris]

nice job manny. looks good. you don't want to make me an intake pipe do ya? lol
cai or sri. i don't care

[macavely]

nice work Manny.. damn kid you have come a lone way from the first time we talk back when.. its nice to come back on here and see you are still doing what you love.. I think I might have you come down here when I'm ready to turbo the tC..

[presure2]

well finally found the time to finish up the IC piping project, and also made them an intake.
the car is just about finished, started it for the first time since doing the tbelt and water pump ect. it runs sweet.
a couple more pics.

[stetsonaw]

good job manny, nice work, looks great!