TFS: How to Build a Custom Intercooler
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- Опубліковано 30 бер 2016
- A detailed fabrication video highlighting the measuring, fabrication, and installation of a custom built intercooler.
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I stumbled onto your channel. My first thought was "another hack that thinks he's a fabricator". There's no shortage of those on UA-cam. Boy, was I wrong! You are the real deal and present the info very well. Every time I watch you, I learn something. Thank you.
That is a very kind compliment. Thank you!
I am 10 months later than he was but I second that! Awesome skills brother!
Josh Gandy. I'm jumping on even later; had thought the same thing - until a few minutes into the first video.
Today is 5/11/8 and I've been watching your videos and am learning quite a bit from them before I get into welding myself I quadruple the original comment!!!
Very true!! I find it hard to even watch anyone else if TFS or Welding Tips and Tricks doesn’t have it I have a hard time watching. Not only are they awesome fabricators but the explanation behind every step they do is amazing!
I've been working on military aircraft structures for 17 years & I'm currently learning aerospace welding (finally!). I've got to say that so much of your sheet metal design method is spot on. I'm watching your videos to give me tig tips and they're so easy to implement and better yet, explain to course mates and instructors!
AD Aus AF
What’s amazing about this video is it’s very “diy” achievable. It’s pre break and other fancy tools. Love it!
Back in the late 80"s I did a side hussle welding up inter coolers for a shop, I always back purged the inside with argon made the welds come out much better.
Great video, the intercooler turned out great!
Sorry about the accident and injuries, I hadn't heard about it until I watched this video.
I'm going back and watching all the videos I have missed and I just got to this one.
Awesome build! Looks beautiful!
Thanks!
Hey Justin, been a fan for a long time and learning from your vids. "UA-cam Certified" Just happened to stumgle upon this video because I'm at this stage of my build. Awesome job and thanks for the motivation! I noticed the Humble Beginnings of the old garage, so cool to this that anything is possible of you dream hard enough!
Great episode as always! Glad you made a speedy recovery from that accident. Thanks for sharing.
-Ethan
+efitter7 Thanks!
Ah a fellow Ethan
Great skills thanks for sharing
Glad to see your doing well and thanks again for another excellent, very inspiring video!
+msturtev78 Thanks!
Sorry to hear about the accident and a shame about the truck but as long as you are ok all is good. Now you have a opportunity to do another project great videos keep them coming.
Dave
+David Cashin Plenty more in the future! Thanks!
Genius... i love the work and the narrations...keep it coming ..ohhh.. build an intake... i want to see that..
Awesome build as all you do is perfection. Sorry to hear about accident. MiniTruckers for Life!!!
Awesome job, glad your OK
Thank you!
wow! very very nice work!
Great job on the fab work keep'm coming, sorry for your loss...
This was beautiful
+Conor Curtis Thank you!
always something to be lerned from the fabricator. top man.
Thanks!
Awesome videos, I am sorry for the loss of your truck but thankfully you are doing well. Cars/trucks can be replaced, people cannot. Cannot wait for the next video!
+Dbear326 Thanks!
truely inspired by your videos dude lots of respect and best wishes from Essex Uk
Awesome! Thanks for watching!
You do some damn good work
Brother, I applaud you for sharing your techniques. I do a ton of fabrication myself (name) and I have to admit that your answer to several unique problems over your video series is refreshing. You keep it no nonsense and you do layman math/layouts which is phenomenal. I would love to see if you have any sources on radiator cores. JEEZ that business seems to be a dark secret. I used this video as a reminder that I can make a radiator for a custom application if I can just find the parts. Again, cheers and wishing you great success.
Thank you. I usually source cores from Bell. You can also go to a local radiator shop and see if they can build you a core. Most of them can. If not, ask where they source cores from.
Nice sticker from KBPI. In Colorado. Thankx again for the helpful information. I learning. With out these videos. I think it would be a slower process
Awesome. Just awesome video.
Thanks!
Greetings from Lancaster PA, Hope you're doing better. I've been searching how to build a front bumper for my fj cruiser and stumble with your videos and man how much great info you're giving out. Not yet sure about making the bumper of tubes or sheet metal but would like to see a video working on an off road metal bumper.
Thanks.
I often make off-road bumpers but time to shoot the video is the killer. Most customers are on tight timelines, but I'll get something together one day.
@25:58 13B rotor housings :P spotted. Great videos man. Im gonna get my tig working and attempt to build a manifold for my RX7 T78 turbo. Would not have the confidence to do it without your videos.
Right on. Check out the turbo manifold vids I have if you havent already. It's not a rotary, but the concept is similar.
love it
+lewis smith Thanks!
You're the man wish I could have you build my rollcage for my cj7
People ship projects to me from all over. If you're in the states, it's very possible.
The grinding table is slick as f*** ! 👍
Another great video! Looking forward to moving back home next year and hoping to possibly meet you and work together on some things!
+Metal Bill Right on! Feel free to swing by when you make it back here.
Amazing Vid! I'm about to build one myself. Quick question, how thick was the aluminum that you used for the end tanks?
I got you ..thanks for replying right away I appreciate that buddy
+Juan Blanco No problem. Thanks for watching!
Awesome man, love your videos! They inspire me to do more custom work on my car!
+GoodeZilla Right on! Good luck on your work!
+The Fabricator Dang man, I commented before I saw the end of the video. Sorry to hear that the truck was a loss, and I'm glad that you are doing well now! Take care!
GoodeZilla Such is life... Very sad to have lost it, but I can always build another.
Bro, you do nice work, just found your channel!!
+That Guy There Thanks for watching!
Where did you buy the intercooler core from? Awesome video!! Yours is the most educational video I have found by far and thanks a lot!!
Im glad u made it out of the accident ok for the most part.... u do very nice work keep it up and keep the videos coming.... thank you.
Thank you. I made it out alive which is all I really care. I can always build it again!
can i apprenticeship under you ? haha you sir are talented been wanting to get into metal fabrication for the longest time
+Godzilla Speed My current apprentices are volunteer camera operators. They come in on their own time and learn what they can when not shooting vids.
Sorry to hear of your accident. You've inspired me to be out in the shop all weekend - that's half the battle!
+mccanlessdesign Awesome! Hope you get done what you set out to do!
+The Fabricator
It'll take a while - I'm stretching my chassis 10" for a different (mid-engined) drivetrain. Been planning and CAD modeling for a couple years - you've convinced me to get off my butt, get a tubing bender, and start!
mccanlessdesign That sounds like a really epic build.
Love your stuff man, suave at 30:10 haha
Haha, right on. Thanks for watching.
I need a bash bar like that for my truck thats sweet
Hi is it would be easier to weld bungs first or how you going to hook everything up
Wow sorry for your lost love the video saw this for the first time and am doing a similar build . I would like to know ir u can do a oilcooler mount just like that one please let me know thanks.
I can. Just email me on the website. thefabricatorseries.com/
I'm super happy I found this channel.. Fantastic content! Would a custom radiator be similar to making an intercooler? Or would it be different? Keep up the killer work.
+GetBlitzified A radiator is pretty much the same.
I enjoy your videos ,I'm a pipe fitter ,and I recognise talent when I see it ,you are a great fabricator , I like to start doing custom work , I just dont know to get started ...any tips you like to share
+Juan Blanco This may sound like a generic kind of response, but you have to decide what you want to build first. After that, the work starts flowing.
I need to learn how to weld... But first I need a welder... Any recommendations on a good starting tig welder?
+Kalvin Malli (ThatBurgundy240) A welder is an investment. If you are serious about learning howto weld, you need to buy a good welder. The reason why is because a low dollar, or "budget" welder will end up teaching you how to work around its deficiencies. You end up picking up a ton of bad habits with bad welders which will never get you far in your career, or even serious hobby work.
I usually only recommend two brands: Miller, and Lincoln. I have used and owned both brands, but for my money, the Miller seems to put up with far more abuse. I always suggest that the Miller Diversion series welders are a great starter TIG. They can be owned for under $2K, and they will take some serious abuse without forcing you to pick up bad welding habits.
+Kalvin Malli (ThatBurgundy240) Nice to see you here Kalvin!
+Kalvin Malli (ThatBurgundy240)
Buy the best welder you can afford. I went the budget route with a Longevity. It works fine but I definitely wish it could do more.
rules do not apply to me lol ..i fell you my old junk welder is a joke
honestly i think the money is better spent doing night school at a community college. Learn on a good machine to learn proper technique. You're gonna need to just run beads for weeks. The amount of gas, metal, filler wire, electricity, tungsten, grinding wheels. all adds up. Especially practicing on aluminum.
An amazing episode but what a sad ending! That sucks!
Well, now that I know how to custom build an intercooler, all I gotta do is build the Hot Rod. Thanks! JD
awesome!!! glad to hear you're ok!!!!
+Mr. green Thank you!
A big fan of your work, I'm sorry for your unfortunate accident.
Hi mate I know its a long shot but hope you can help.
What TIG Welder would you recommend to do this kind of work? Mid range welder
Also what settings are you using to weld all that up?
Many Thanks!
Hey guy, love your work, I've learnt so much from your channel. Well done on a very watchable series!
Quick question, not relevant to this episode, what is the type of pipe bender you use? all I can find are hydraulic press type, and yours seems to bend without crushing like they do.
thanks in advance
Jason (Australia)
+Jason Lee Hey, thanksfor watching. Check out this episode ua-cam.com/video/3n_lf2RHIPs/v-deo.html
It's loaded in 3 separate pars which detail some of the basics of bending from tools to techniques.
My question(s) about Intercoolers/Cores: 1. Are there cores you recommend that I can run with a coolant like Valvoline Zerex?, 2. Can I remove the factory radiator in my '02 Dakota and run just the intercooler as standalone?, 3. How do I ensure the best, most accurate, and "tightest" fit possible?, and 4. If I can run the intercooler as standalone, how would I build the piping to work or fit over where the original factory hosing would've fit?
Been looking at a bunch of videos like this trying to find one that builds an oil cooler. Same idea, just different style cores... Can you even buy plate style cores that you can cut to size? Can't seem to find those anywhere... Got a couple of cherokees that need all of the cooling help they can get... would like to do a trans cooler and an oil cooler in each... and fitting those in a 7" tall crossmember kinda sucks to find (especially with side ports instead of bottom ports)
Rest in peace little Ram 50.
How does one properly deal with the weld bead on the edge of the intercooler, where it mates to the flat edge of the tank? Garrett cores have a bead and as such it's a fairly uneven surface to weld the flat tank edge to, resulting in some small gaps.
How thick material u use for your intercoolers 2-3mm?
awesome videos !!! what's that green tape you always use ? is there any type of substitutes at the a hardware store ?
That is PET Tape. Here's a video about it where I put it up against a few other common tapes:
ua-cam.com/video/KV3rLBetM4I/v-deo.html
PET tape is available on my website if you are interested in getting a roll or two.
Left hand sun tan, yeehaw!
nice work.watt would be the Price for the job you did on this project?
Recent subscriber. Trying to catch up on all your video's, excellent channel. Sorry about the truck, too bad you couldn't salvage it.
It was sad to see it go, but I saved a big hassle by parting it out and letting it go. Sometimes it's just better to consider all of the variables regardless of attachment.
Thanks for the sub!
Love your builds! Subbed to your channel yesterday
Only thing missing is a better camera, maybe some better lights in your work space and a better microphone.
Keep up the god work! :)
tullgutten Watch the newer vids. They're all shot with a much better camera, microphone, and lighting. Thanks for the sub!
I see, definitively better quality ;P
I was just remembering the Green screen "selfie videos" you have is kinda low quality or out of focus, still worth the watch anyway!
All the stuff I post on our social media pages is usually shot from my phone or tablet which has a really messed up camera haha. Its tough to keep nice things in an environment like this.
Super interesting videos. Shame the truck is gone.
I miss it, but life goes on. Thanks for watching!
where you buy that panel to make the intercooler?
The biggest lesson I took from this video was, you really need to switch to metric.
If you're open for suggestions on a future serious I'd like to add one. I'd like to build a small, enclosed tow-behind trailer. Specifically, one to meet the rules for Hotrod's Drag Week. The rule book states "Each competition vehicle may tow a single trailer with a maximum cargo area no larger than 142 cubic feet, which is the advertised size of a standard 4x8 box trailer (which is 4’1” wide, 4' tall, 8’1” long)" I'd pay good money for this if you are interested. Either way, love your videos.EDIT* The dimensions above are the max allowed, something half that size would work for most people.
+Whothrewpoo I'd have to have someone hire me to build that here so I can put it on video.
How was your first time welding was it intimidating and how should I start to fab my own stuff
I was more excited than intimidated. Start with an education and understanding of what you want to create. If you want to weld, take a welding class. If you want to design, take a drafting and design course. Once you have the formal understanding, the rest is hands on.
So where do you get the intercooler at unfinished like that and the other parts
Did I miss it in the video, or what machine settings did you run to weld the intercooler? Also, what cup sizes, appx stickout, etc would be helpful too. I am trying to build my own A2W intercooler, and let's just say I'm not as good as you. lol
My settings may not be the same as yours. There is no universal setting. It takes practice to get it right. I usually leave out the settings and other info because it can vary greatly between welding machines and the people doing the welding.
old video yes I know but can you build a air to water intercooler. I want to build one because why buy when diy. but want clean tutorials like you provide in all your videos
I've been wanting to watch this video for a while. I am currently planning a project for which i'd like to fabricate a custom intercooler. Do you have a preference on intercooler core brand ?
I remember seeying a picture of the truck on instagram soon after the accident. sad it had to go.
thank you!
I typically stick to American made cores. Bell Intercoolers is my favorite for everything. Garrett cores are a close second for common sizes.
China brands weld a little weird and do not produce the best performance results, so I avoid them as often as possible.
What thickness aluminum do you like when making end tanks? .090?
+Andrew Fleming Typically 0.090", but race versions are even thinner.
sorry if i missed it in the video, whats the thickness of the material for the end tanks?
+Will Shriver I think that was .090". I might have mentioned somewhere in the comments.
I just came across your channel last night. Im a machinist by trade. You would greatly benefit from a cnc . There really cheap now a days for the home guy. You may want to look into one. I love your channel though .
+Mark Rich I own a CNC. It will probably be seen in some future vids. Thanks for watching!
+The Fabricator
Cool , I work at Sikorsky aircraft on a Doosan hp5500 , model in solidworks and solidcam. I also own a smaller 4 axis boxed mill at home. I love automation.
Cool channel though .
Mark Rich Awesome. I do all of my CAM with Mastercam. My CNC is only a router, but it definitely does the job.
how thick is the aluminum plate?
Do you want to do the work on my evo 😃 i have heaps to do!
The catch... i live in NZ..
Thankyou for inspiring us followers man! Your work is definitely 👌
A fish with 9 lives! That's awesome
Where did you get your protractor? Been looking for one the same for ages
+Thomas Vickery Hardware store. You can also order them online. They're often called "angle finders"
A very talented fabricator. Just one thing that bothers me. Is the proper terminology for the part. An intercooler is so named because they are normally inside the intake manifold and are an air to water cooler. The type that is being built in this video. Is an air to ate after cooler. So named because it cools the are after the turbo by radiating the heat to the air
what determines the inlet size
Is your band saw a dedicated metal cutting model, or a wood cutting one (that works great for aluminum)?
+Hammerhaus Kennel It's technically for metal because it is built so heavy, but stick a wood blade in it and it will cut it.
+The Fabricator what brand is the band saw? or is there one you recommend? that thing saws through the aluminum like butter
infinite7z13b It is a Proter Cable. The blade is what does the work. A good blade (properly broken in) will slice up just about anything.
how mm is the aluminum plates??
Can you give more details about getting it pressure tested? Is there a place you had it sent out to?
You can pressure it yourself by capping the ports and filling with air. Use either a gauge to monitor drop, soapy water solution, or submerge it.
I usually go to a local radiator shop where they do all of that for me along with adding the coating. Any radiator shop should ba able to manage a pressure test.
I figured it could be tested at home but since you said you sent it out, I was curious. Awesome! Thank you so much for the super quick answer! Keep up the good work!!
Where do you get just the cores from?
+ratgreen This one is a Garrett, but I usually buy from Bell Intercoolers.
Hello! Really nice job. Which model is this circular saw? I never saw one of this for metal. Sorry to hear about your truck.
+Vicente Costa It's a Dewalt DW715 with a carbide metal blade fitted to it. It woks well with aluminum but the saw speed is too fast for ferrous metal.
Thanks. I almost bought Makita LC 1230 last week, but waited to see your answer. What do you think about it?
Vicente Costa That one is specific to metal cutting. I haven't personally used it, but most people have reported back that it works well. The blades are the killer for future costs, so make sure you use the correct blade for the correct material.
Quick question, Are you a CO native? Just asking because of the KBPI sticker on your hood. Thanks for the Great vids!!
+dutton2003 I'm a Vegas native. I just happened to live in Denver for a few years.
Why didn't you cut the hose joiner in half and use it for both the intake and outlet?
teamEP789 That would make a very stubby I/O which could lead to leaks and clamping issues.
where do you get blank intercooler cores like that? I got a drift car project coming up I'd like to do something like this on.
I usually buy Bell Intercoolers cores or Garrett. A quick online search will pull up thousands of companies.
Awesome! Thank you! I've learned a lot from your videos that I'm going to apply on my build, especially the tube chassis and bash bars you did for the time attack car. It's going to be a little different from typical drift cars, 94 Mustang gt with a twin turbo ls swap. Gonna be a long process, but very satisfying when finished. Thanks for continuing to do the awesome work you do with these videos, teaching average Joe's like me to do quality fab work.
Terry Cape. drift core build you better have a wielded differential
Forget i sayed core
Where do you get the intercooler cores from?
Zack Thomas I typically like to order them from Bell. Sometimes I use Garrett cores. Those are the only two I trust to be constructed with quality.
How did you gain your knowledge? Can you give a detailed answer please? Did you attend trade school? if so where? Math background? Who are your mentors? Can you give me some info along these lines?
Knowledge was gained from formal training (many schools) and "old heads" of the industry who were willing to teach. The rest is first hand experience gained over time with a ton of practice. My background is Engineering.
There really isn't "one place or one way" to learn this field. It is all based on several single careers and fields combined into one field that is only mastered from first hand experience.
what kind of intercooler core do you like to use?
+ieatls1 I typically use Bell or Garrett cores. Garrett has all the common sizes while Bell has everything else, and they're USA made.
+The Fabricator I appreciate the info. I've never built an intercooler, is there a difference on the weld quality on these compared to the China brands? Thanks!
nicee one!!! i really was wondering how someone can make k custome intercooler and here it is...^_^ new sub :P hey in your intro i saw a engineering program.. im thinking to make a new project for a drift trike with my classmate and maybe that program will be useful can u tell me what program it is? Appreciated
Thanks for the sub!
The software I use is called Mastercam.
thanks!!! i really i appreciate your help, that program is going to help me a lot with my own projects...!!
supplies used ? wanting to try this
Andrew Williams Its up to the requirements of the intercooler itself. Everything I used for this build is in the vid.
kbpi 🤣 didn't know you were from my home state.
What kind of tig welder do you have? I am trying to invest into a quality one so I can teach myself and not have to fork money out everytime I need something fabricated
Miller Diversion 180
did you make the core or buy it
+Fat “Cajun Thibodaux” Cajun Cores are made with big machines in factories where they are typically vacuum brazed. It's a whole lot of machinery. This core was bought.
+The Fabricator I was just wondering is this more cost efficient to buy a core and fabricate it up yourself or is it cheaper to buy one
I've just subscribed to receive you videos. So far they have been awesome but for one minor issue. I am very hard of hearing and sometimes when you do not speak directly to the camera I miss about half of what you say. I was wondering how difficult would it be to include closed caption or the text to your videos. I know it would be a PITA to do just for one guy but maybe a pole from your other subscribers might help with the decision. Thanks and keep up the great work!
+scott brazale No pole needed. It will take some time, but I will make sure it gets done. Thanks for watching!
+The Fabricator Awesome...thank you!
Sorry to hear about the accident. Uninsured people should go to jail. I'm glad you recovered 100%.
Anyway, how thick was the aluminium you used for the side tanks?
+makirompe It sucks to have lost it, but I can always build another one. The aluminum was .090"
thinking of buying a cheap tig welder to get me started so I can practice welding tubes together etc, purely for my own stuff, as I apparently cant buy exhaust system for my car......... would it be worth my time buying a realy cheap tig to start with?
If you're serious about fabrication and welding - don't buy a cheap unit. If you just want to work on the side and do some hobby builds/projects - grab the AHP AlphaTIG 200x. It's a solid machine for the money and offers a lot for very little.
where can I buy cores. water to air cores too
ja st The best place is Bell Intercoolers. You can buy a bunch of China cores on eBay, but they kinda suck to weld.
The Fabrication Series Bell as in Bell Engineering, the same people that make the Miata turbo kits?
i enjoy your videos, and have learned a few tricks from you. I mainly build intercoolers and intakes for the C7 Z06 (@nutsoverglass on instagram) interesting to see someone else's process.... extremely different from mine.
That's the beauty of this industry. The same part can be built 100 different ways haha. Thanks for watching!