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Discussion Starter · #1 ·
So once again, we're tweaking with Tweak (Jonny_Blacks car)... lol! Only this time, things are getting juuuuust a bit more serious in the intercooler-department :)

Today we're installing a manifold that i've had laying around for a while... it'll allow him to finally have a/c back. Also, we're installing a PWR liquid-air intercooler that i've also had laying around forever, to replace his air-air one.

So, for now, all i have done fabrication wise is a single mount for the intercooler, and the cold-side charge piping... still needs to be finish-welded of course, as it is just tacked together for now, but it was already looking cool enough, i figured i'd go ahead and start a thread about it.. hehe.

Anyway, enjoy the pics! I'll post more up here as we get this turbo setup done on his car.. should only be another few days working at it after-hours and stuff :p





















Tweak will once again, be siiiiiiiiiick :twisted:

I still have a custom aluminum water resevoir that i'm going to make, which will sit right next to the intercooler. The radiator for the water system is one out of like a 750cc Honda motorcycle or something. Still using the same turbo, but this build is happening in preparation of muuuuuch more to be done to this car to bring it up a few rungs on the speed-ladder :p

yAy!
 

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If I was going turbo I would like to go with the same setup. Nothing says sleeper like a huge turbo with no FMIC.
 

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actually there is a couple of reasons for this change.
1. This perfectly good and amazing intercooler was lying around and I just love the idea of a water cooled setup.
2. I needed to upgrade the setup for some bigger power numbers soon anway.
3. A freind was in despreate need of a stronger turbo manifold and I sold him mine for a very cheap price.
4. I love stealth also.
5. And this is the most important one. If the temp outside is 95+ degrees, and I am driving highway, say anythign above 70 mph, the cars cooling system cant quite keep up. you would see the temp guage slowly creep up. and I found that very annoying. so taking out a FMIC from in front of the radiator should help things out considerably I should think.
6. I really miss A/C.
 

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Discussion Starter · #8 ·
7. Cuz i luv welding aluminum

8. Cuz a few people told me that mounting this intercooler in a street car wasn't feasible (tis in thur, ain't it?)

9. Now tweak will be a boost ninja!

10. Cuz i'm bored

11. ............. WAFFLES! :p

8)
 

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ComposiMo said:
7. Cuz i luv welding aluminum

8. Cuz a few people told me that mounting this intercooler in a street car wasn't feasible (tis in thur, ain't it?)

9. Now tweak will be a boost ninja!

10. Cuz i'm bored

11. ............. WAFFLES! :p

8)
Preach on brotha!!!

Welding outside corners on AL FTMFW!

But Pie> waffles.
 

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Discussion Starter · #10 ·
I4sillypwr said:
Welding outside corners on AL FTMFW!
Thats my favorite part! Dunno what FTMFW means, but i got lots of practice at outside corners welding up a bunch of radiators for some race cars... anyhoo, just back the amperage down a ton, and get creative with filler a bit... also, tilt the torch towards the corner, so that 'aerodynamically', the shielding gas won't create a vortex pocet around an edge, and introduce oxygen to the mix by accident ;)

I4sillypwr said:
But Pie> waffles.
Ppffffffftttt! wha-ev-er! :lol:
 

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ComposiMo said:
Thats my favorite part! Dunno what FTMFW means, but i got lots of practice at outside corners welding up a bunch of radiators for some race cars... anyhoo, just back the amperage down a ton, and get creative with filler a bit... also, tilt the torch towards the corner, so that 'aerodynamically', the shielding gas won't create a vortex pocet around an edge, and introduce oxygen to the mix by accident ;)
I have no flipping clue what you mean by tilting the torch towards the corner man. Which corner do you mean?

ComposiMo said:
Ppffffffftttt! wha-ev-er! :lol:
Dude that's so gay :p
 

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I don't think comparing pie with waffles is a fair argument. Waffles are obviously meant for morning/early afternoon consumption, as they are a part of breakfast or brunch. Pies are aimed towards being an after-meal treat or dessert. They both have the perks for certain times of the day.
Perhaps we can compare pie with cake, or waffles to pancakes. Poll, anyone? :wink:
 

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Discussion Starter · #13 ·
I4sillypwr said:
I have no flipping clue what you mean by tilting the torch towards the corner man. Which corner do you mean?
Ok, so now i'm lost if you don't know which corner you're 'flippin' welding on... maybe i just misunderstood what you were saying in the first place... lol!

Blah... nevermind. I've got more welding to do so Jonny can have his car back sometime this month... haha!
 

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ComposiMo said:
I4sillypwr said:
I have no flipping clue what you mean by tilting the torch towards the corner man. Which corner do you mean?
Ok, so now i'm lost if you don't know which corner you're 'flippin' welding on... maybe i just misunderstood what you were saying in the first place... lol!

Blah... nevermind. I've got more welding to do so Jonny can have his car back sometime this month... haha!
Outside 90 deg corner. Prepped with the edges square on each piece so they form a nice V to lay the filler in.

Are you talking about a more upright torch angle? I just don't know what area you are talking about tilting the torch in relation too.
 

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Discussion Starter · #15 ·
A 2-sided edge, i.e. like in the middle of the edge of a box, usually goes with the torch straight up to the weld, and not tilted in any way... kinda like this:



To me, this is one of my favorite welds on aluminum, because it is rather easy to start and flow, and it creates a killer looking bead.

But anyway, what i thought you were saying, was as you approached a 3-side corner, you were having problems... in that case, i drop the amperage down, and tilt the torch so that it is pinted more into the triangle, like if you were looking straight down on a pyramid... that way you have even gas flow over all sides, rather than creating a pocket of air around a corner.
 

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Discussion Starter · #17 ·
New Updates!

Ok, so after a few hours spent tonight messing with it, we have the intercooler and charge piping made... all 1 piece to :) That is a very nice thing about this setup... less couplers to have and blow off... actually, with this setup, it'll be impossible to blow off a coupling, because it simply won't be able to move enough to do it.. hehe. How bout some pictures?

So, here i am welding up the setup:







Yes, i really am too damn sexy for leathers... hahaha! j/k...

And here it is completed... the only thing left to do, is add the BOV flange, which i'll have tomorrow, and we're set!













And here is a part that i really am proud of for whatever reason... i messed with it earlier, but basically, it is a 2.5" to 3" transition in the middle of a bend. I also didn't have any 2.5" piping, so i cut down 3", and re-welded it. Both pieces are fully welded inside and outside, and then the outside welds were smoothed out to make it look sorta seamless... it just SCREAMS sex when you see it in person :p



Yes, there IS a welded seam that runs right down the middle of these pieces... but its nice and smooth looking :) :




Overall view:


And of course Jonny chilling out next to his improved baby:


(note how dirty he is... yep, he was working OVERTIME on his car tonight! hahaha! Just messin with ya Jon ;) )

Anyway, next up is to rebuild the condensor support with something more 'custom', mount the heat exchanger for the water lines, mount the water pump, and build a water tank out of aluminum... good times 8)
 

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good god doesn't she look beautiful! :cry:

I miss her soo much.

a masterpiece john...its looking fantabulous! hehe :lol:
 

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I don't know much about FI... but do you also get an advantage with that setup because the charge piping is so short, like, you don't lose as much pressure between the turbo and the intake as you would with a FMIC?
 
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