How to - Make your own chargecooler, Going one better than TTE Options

[Insanity-74]

two pairs of leather gloves, one to wear and one to hold the metal with and you'll be good to go

That would be a good start...bending the metal hot isnt a problem...I just use tools to hold it with...the problem is I keep forgetting that the metal is very hot...and stays very hot for a good long while....when its all bent into shape I think..."Right...just put these bits together to make sure its all the right size/shape etc" pick the bit of metal up....unfortunately its usually with my bare hands.....the resulting "TSSSSSSSSSSSS" sound as my skin sears itself to the metal and the following "AAAaaaaaargh" in pain still dosnt appear to be enough from stopping me doing exactly the same thing ten mins later....you`d think I`d learn wouldnt you...but no....my brain appears to be missing the part required to remember that metal stays hot for more than 20 seconds.

Havnt done much this weekend...been at the Toyota Sprint Series, but I`m gonna get my arse into gear this week and try and get the fabrication completed up to the point where I`ll be ready to form the inlet and outlet pipes, but this needs to be done on the car to make sure everything is a perfect fit.

This post has been edited by Insanity-74: Jun 15, 2008 - 2:29 AM

[presure2]

my brain appears to be missing the part required to remember that metal stays hot for more than 20 seconds.

WOOT.
now i know im not the only one.

just FYI, it also stays hot for a good bit after welding as well!
BWAHAHAHAHa

[devilsden97]

my brain appears to be missing the part required to remember that metal stays hot for more than 20 seconds.

WOOT.
now i know im not the only one.

just FYI, it also stays hot for a good bit after welding as well!
BWAHAHAHAHa

lol i love 6gc.net

[97lestyousay]

Nice work, very impressive craftsmanship. I can't wait to see it all finished.
You are making me realize how good I have it working in an air conditioned shop.

[6strngs]

two pairs of leather gloves, one to wear and one to hold the metal with and you'll be good to go

That would be a good start...bending the metal hot isnt a problem...I just use tools to hold it with...the problem is I keep forgetting that the metal is very hot...and stays very hot for a good long while....when its all bent into shape I think..."Right...just put these bits together to make sure its all the right size/shape etc" pick the bit of metal up....unfortunately its usually with my bare hands.....the resulting "TSSSSSSSSSSSS" sound as my skin sears itself to the metal and the following "AAAaaaaaargh" in pain still dosnt appear to be enough from stopping me doing exactly the same thing ten mins later....you`d think I`d learn wouldnt you...but no....my brain appears to be missing the part required to remember that metal stays hot for more than 20 seconds.

Havnt done much this weekend...been at the Toyota Sprint Series, but I`m gonna get my arse into gear this week and try and get the fabrication completed up to the point where I`ll be ready to form the inlet and outlet pipes, but this needs to be done on the car to make sure everything is a perfect fit.

a pair of welding gloves should help you out with that

[Insanity-74]

two pairs of leather gloves, one to wear and one to hold the metal with and you'll be good to go

That would be a good start...bending the metal hot isnt a problem...I just use tools to hold it with...the problem is I keep forgetting that the metal is very hot...and stays very hot for a good long while....when its all bent into shape I think..."Right...just put these bits together to make sure its all the right size/shape etc" pick the bit of metal up....unfortunately its usually with my bare hands.....the resulting "TSSSSSSSSSSSS" sound as my skin sears itself to the metal and the following "AAAaaaaaargh" in pain still dosnt appear to be enough from stopping me doing exactly the same thing ten mins later....you`d think I`d learn wouldnt you...but no....my brain appears to be missing the part required to remember that metal stays hot for more than 20 seconds.

Havnt done much this weekend...been at the Toyota Sprint Series, but I`m gonna get my arse into gear this week and try and get the fabrication completed up to the point where I`ll be ready to form the inlet and outlet pipes, but this needs to be done on the car to make sure everything is a perfect fit.

a pair of welding gloves should help you out with that

So would half a brain...I appear to be missing both

my brain appears to be missing the part required to remember that metal stays hot for more than 20 seconds.

WOOT.
now i know im not the only one.

just FYI, it also stays hot for a good bit after welding as well!
BWAHAHAHAHa

Excellent...more oportunities for me to burn myself....I cant wait

This post has been edited by Insanity-74: Jun 15, 2008 - 3:15 PM

[DEATH]

Update?

[Driveby]

Yeah slacker c'mon hurry up.
Been fiddling with other things instead, havent you

[D-Man]

Update?

[Insanity-74]

Sorry, been busy over the past few weeks, but its nearly done, nothing welded yet (hence the tape) but everything is cut to size and shaped. Had the final fitting yesterday with the brackets that I made in place to support the chargecooler off the engine a little.

First fit....looking a little unlikely that the bonnet will close



but it did and with room to spare

The water inlet/outlet end tanks



it does stick up kinda high



but theres a good gap to help keep it away from the hot bits of the engine



the rear end tank was a PITA to make, as its all twisted to make everything line up correctly and to make enough clearance for the various bits n pices in the engine bay

[DEATH]

Damn that's nice - get it welded already!
Oh yeah and when does mass production start?

This post has been edited by DEATH: Aug 5, 2008 - 6:41 AM

[Insanity-74]

Awaiting the return of the first bit of welding which was sent off at the beginning of the week...so touch wood, it should be all done soon and ready for pressure and leak tests.

[chacha]

I would like one too bro...let me know ASAP...just collecting parts...run test on it to see how it performs once done and compare result with FMIC...thanks for your brillant mind and initiative courage to make the celica stand more out and proud...looks great btw.

[Insanity-74]

I would like one too bro...let me know ASAP...just collecting parts...run test on it to see how it performs once done and compare result with FMIC...thanks for your brillant mind and initiative courage to make the celica stand more out and proud...looks great btw.

Cheers bud The first lot of welding has been completed and I`m waiting for it to be returned for inspection and DPi test.....some more bits will be sent off later this week, then unfortunately the welder goes on holiday for a couple of weeks so I`ll be stuck for a while.....I`ll be using that time to make final adjustments and make sure everything is aligned 100%....unfortunately its not a quick process but good things come to those who wait.

If anyone wants to make there own I`ll produce detaled drawings/dimensions and suppliers lists once I`m done and I know that it works.

[Insanity-74]

Reaching the final stages now...got the first bit of welding back and its looking pretty good..dressed quite well, just needs smoothing over and polishing up...some more went off today, Looking forward to getting this done and onto the car.

[Insanity-74]

Header tank completed........just needs finishing

[DEATH]

So cool - watching with intense interest

[Insanity-74]

Will be finished quicker than I thought as the welder is fast.......50% welding completed by the weekend....then some more lining up and the final welding finished next week.......then 5 bar pressure test to see if it leaks and then ready for fitting/testing and away we go...cool running ahead

[DEATH]

UPDATE!

[Nial]

the welder is back from holiday on monday (tomorrow) so it should all be starting again soon......maybe 2 weeks maximum before its on and running. Have bought all the pipework and heat shielding required and have bought a charge air temp sensor to monitor charge air temps.

Getting excited now as its been over one year since I thought of this idea....cant wait to get it on...I hope it works cause I`m going to look very silly in deed if it dosnt