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Location:
Adelaide, SA
Registered:
May 2002
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Intercooler end tank design
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Thu, 18 August 2005 14:45
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Hi all,
Got a quick question, I searched but didn't find an answer.
How thick should the aluminium for an intercooler end tank be? I am designing the end tanks for my garrett core. It seems to have 2-3mm thick aluminium on it, would it be best to stick to this thickness?
Also, since I am designing and doing everything bar welding the tanks up, would It be worth making some sort of deflector to help distribute the air more evenly over the core? I have a feeling it may not be worth it in my case, the intake side of the core will be coming from the bottom of the end tank, which I guess would mean it'll spread across the core more evenly.
With all those cheap intercoolers out there now, I am ever so tempted to scrap the idea of making mine up and just buy one of those. I've seen them as cheap as $280 or so!! Spent $150 on this core, haven't bought materials or paid a welder yet. $130 more would see me with an already fabricated core with mounting hardware.
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I supported Toymods
Location:
Perth, WA
Registered:
May 2003
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Re: Intercooler end tank design
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Thu, 18 August 2005 14:51
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those cheaper coolers are down to 150 delivered right now
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Location:
Adelaide, SA
Registered:
May 2002
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Re: Intercooler end tank design
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Thu, 18 August 2005 14:53
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Dang... that makes me feel tempted. I'm sure a garrett core would sell for lots on ebay! 
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Location:
Adelaide
Registered:
September 2003
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Re: Intercooler end tank design
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Thu, 18 August 2005 21:55
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2 - 3 mm is a good idea.
Don't worry about deflectors as you have summarised. Avoid sharp bends if possible, and yes, depending on how much work it is to fit in (plumbing and brackets), the cheap "hybrid" or other brand coolers will work pretty well for what they cost.
Cheers
Michael B
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Location:
Adelaide, SA
Registered:
May 2002
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Re: Intercooler end tank design
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Thu, 18 August 2005 23:51
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I'll persist with the garrett core... it's better to say you have a garrett core than a "cheap hybrid copy"! 
I can imagine i'd be spending at least another $150 on plumbing with a hybrid copy. The major expense would be the 2" to 3" adaptors. And anyway, creating my own end tanks means everything will fit correctly.
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I supported Toymods
Location:
Perth
Registered:
May 2002
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Re: Intercooler end tank design
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Fri, 19 August 2005 00:06
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| HyDrA wrote on Fri, 19 August 2005 07:51 |
The major expense would be the 2" to 3" adaptors. And anyway, creating my own end tanks means everything will fit correctly.
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Yes, who's STUPID idea that was I don't know.
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Location:
Adelaide
Registered:
June 2002
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Location:
c'town, NSW
Registered:
May 2002
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Location:
Adelaide, SA
Registered:
May 2002
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Re: Intercooler end tank design
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Fri, 19 August 2005 02:33
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JCMF - Some retard who thought 3" intercooler pipes are fully sik mayte!!
MS-75 - Sounds like a plan. I'll have to go and buy some 3mm aluminium sheet next week, along with a bit of 2" aluminium tubing... I used to have some, but I might not have it now  I really hope I do still have it because it'd make life so much easier.
rob - Thanks for the link! That's some good reading. I think i'll stick with my current design idea which should hopefully do the job well.
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