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Thread: My A/W intercooler build

  1. #26
    Sick 660r's Avatar
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    I wish I could say I made the tank. My aluminum welds are not that pretty. If anyone is interested, I can get more tanks made. This one has 1" NPT ports incase I upgrade pumps and lines later on.


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  2. #27
    Sick 660r's Avatar
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    Quote Originally Posted by Lonesoldier79 View Post
    Nice work on the reservoir Joe. Good foresight on the location tucking it in like you did. Next build I Wana do the same or keep it close the the cab along with the battery box. I'm screwed if I want to use the bed for storage of anything with significant weight.
    Flush with the wells was important to me. It's a little less than 4.5 gallons which should be plenty. The return port below water level eliminates aeration.


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  3. #28

    Duner's Avatar
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    It's all looking good!
    Duner
    4.7 Turbocharged CC in white - 12's
    5.9 Turbocharged RC in black - 10's

    1999 Dodge Dakota R/T RC Turbo: 10.51 @ 130.13 MPH

  4. #29
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    Quote Originally Posted by Duner View Post
    It's all looking good!
    Thanks Duner. Pump is mounted but it needs final welding and trimming. Considering heat wrapping all the supply line but that stuff cost a small fortune. I'll atleast do it in the engine bay.





    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  5. #30
    Sick 660r's Avatar
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    Intercooler support bracket idea. I would like to make it out of aluminum. Thickest material I can fit is 3/8". Thoughts, suggestions?





    Supply and return


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  6. #31

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    Well thought out and fabricated!!
    As for the bracket, any available option to come off the end of cyl head and up? Since pass side is somewhat supported by both hose connections, if you could come straight up, perpendicular, could be a lighter piece, maybe aluminum tubing.
    Keep up the good work!

  7. #32
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    Thanks. That's the only place I can come off the front of the cylinder head. I hade the bracket going further to the driver side but was not able to check steering fluid. Back of the head is not an option since there is a lot going on with spark plug wires, heater hoses, valve cover breather line, intercooler hoses and throttle body cable. I'm running solid motor mounts so I guess I could come off the top of the frame. Maybe tow aluminum tubes mounted to tabs on the frame and have them meet at one point on the intercooler. Could angle them towards the throttle body so it gives side to side support as well.

    I'm running solid lifters so I want to make everything so that I can remove the support and lay the intercooler between the headers and the inner fender. That way adjusting lash isn't a pain in the ass.


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  8. #33

    Duner's Avatar
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    Looking very nice!

    While they are ugly - I am running quick-disconnects on my water lines for the intercooler to allow me to simply lift the intercooler/airhat off and get it out of my way completely.
    Duner
    4.7 Turbocharged CC in white - 12's
    5.9 Turbocharged RC in black - 10's

    1999 Dodge Dakota R/T RC Turbo: 10.51 @ 130.13 MPH

  9. #34
    Sick 660r's Avatar
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    Quote Originally Posted by Duner View Post
    Looking very nice!

    While they are ugly - I am running quick-disconnects on my water lines for the intercooler to allow me to simply lift the intercooler/airhat off and get it out of my way completely.
    I'm really trying to avoid disconnecting the lines especially considering I'll probably run antifreeze.

    I think I can make a bracket off the front two holes for the LA motor mounts then use a 1" piece of angle iron up to the bottom center of the intercooler. That should be plenty of support and it will be easy to remove when I want to adjust lash.


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  10. #35

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    Quote Originally Posted by Sick 660r View Post
    I'm really trying to avoid disconnecting the lines especially considering I'll probably run antifreeze.

    I think I can make a bracket off the front two holes for the LA motor mounts then use a 1" piece of angle iron up to the bottom center of the intercooler. That should be plenty of support and it will be easy to remove when I want to adjust lash.
    The quick disconnects I am using seal the system when disconnected. They are typically used on heavy equipment for adding and removing hydraulic components without losing or leaking any fluid. I run antifreeze in my system when I'm not racing it.
    Duner
    4.7 Turbocharged CC in white - 12's
    5.9 Turbocharged RC in black - 10's

    1999 Dodge Dakota R/T RC Turbo: 10.51 @ 130.13 MPH

  11. #36
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    Got a link to the fittings. They sound convenient.


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  12. #37
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    Nice work have a turbo kit on my busa done like this workes weet as hell.

  13. #38

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    Quote Originally Posted by Sick 660r View Post
    Got a link to the fittings. They sound convenient.
    I went into Parker Hose Store to get them.
    I'd post a link - but there are literally hundreds of different ones and I wouldn't want to post a link to some that aren't what I'm actually using. You just want "dry-break" fittings in the size of the hose you are running.
    Duner
    4.7 Turbocharged CC in white - 12's
    5.9 Turbocharged RC in black - 10's

    1999 Dodge Dakota R/T RC Turbo: 10.51 @ 130.13 MPH

  14. #39
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    Quote Originally Posted by turbotoys1 View Post
    Nice work have a turbo kit on my busa done like this workes weet as hell.
    Thanks. Hopefully this works out well. I'll monitor the drop in temp and try to get away with only running two fans.


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  15. #40
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    Quote Originally Posted by Duner View Post
    I went into Parker Hose Store to get them.
    I'd post a link - but there are literally hundreds of different ones and I wouldn't want to post a link to some that aren't what I'm actually using. You just want "dry-break" fittings in the size of the hose you are running.
    I understand. The "dry-break" should be enough. What size lines and what pump do you run?


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  16. #41
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    Brace... If it's too flimsy then I can triangulate it off the others ear of the la motor mounts.

    edit: still need to make the pieces to attach it to the intercooler...



    Last edited by Sick 660r; 07-28-2015 at 03:43 AM.


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  17. #42

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    Nice work. I like to check into this thread and see how you're coming with this every now and then.. You're doing everything I'd like to do if I did it over again, especially tucking the reservoir into the wheel well profile, and the support bracket for the IC unit I really dig too. I don't have one on mine. Thanks for taking the time to post pics.

  18. #43
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    Solid as a rock



    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  19. #44
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    I moved the motor down 1/2" and back 1/4" so I had to change the second part of the brace. This is it except for a little more welding and powder coating. Really sturdy



    Added this to keep the lines away from the spring



    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  20. #45
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    Anyone use something like this to insulate the intercooler? I have a buch left over from insulating the garage doors. Trying to avoid spending the money on the DEI insulation sheets.

    http://m.homedepot.com/p/Reflectix-1...025/100012574/


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  21. #46

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    Quote Originally Posted by Sick 660r View Post
    Anyone use something like this to insulate the intercooler? I have a buch left over from insulating the garage doors. Trying to avoid spending the money on the DEI insulation sheets.

    http://m.homedepot.com/p/Reflectix-1...025/100012574/
    I have the same stuff, now you got me thinking of using it on my intercooler. That same insulation is on my fire wall on the inside, and does a great job. Hmmmmm

  22. #47
    Sick 660r's Avatar
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    Apparently the bubbles on the inside are plastic and could melt.


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  23. #48

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    I wouldn't think you'd need it but I'm sure you'll come up with a cool functional design. When running with ice in the reservoir the intercooler has a lot of condensation on the outside. Looks like that matting would be a good choice to use to make a blanket.
    2000 CC
    11.37@122


  24. #49
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    It's sitting right above the headers so in doing everything I can to help. I never plan on going to the track so I won't be running ice. Internet say max temp of 180 for the wrap.


    Quote Originally Posted by BluRT00 View Post
    Part your red sport out and buy a gen 2. Problem solved.

  25. #50
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    When I worked as a welder in a motor home place , they used that for the water tanks , I took a piece , cut it to size and used it under my hood ! Seemed to work ok , but then again it's far away from the headers

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