Welding is Handy

[nab856]

We are working on aluminum intercooler duct work for confined spaces.

TIG....

 

[thegadgetguy]

Don't leave us hanging! Where are the welds??

 

[nab856]

Don't leave us hanging! Where are the welds??

Patience! We still need to decide where and how to mount the intercooler. Then, build the mounts.

Here is the project context

 

[nab856]

Bead Rolling

Keeping coolant hoses in place is important. He made me a die set to bead roll tubing. So, I can use this great cast iron antique.

 

[nab856]

Patience! We still need to decide where and how to mount the intercooler. Then, build the mounts.
View attachment 4174734

Here is the project context
View attachment 4174736

Mounting worked out!

This arrangement fits under the hood. Toyota made the intercooler. He worked out the spacing and mounts. So, I get to do the welding.

 

[evanz80]

I may have missed it, but which vehicle are you working on here?

 

[nab856]

We are using the extra 22RTE mounted on a stand to work out intercooler duct work and plumbing. This finishes a project started on our engine building thread. No idea where these parts will end up.

 

[cruiserpilot]

I used VIBRANT tubing for my FMIC on my 12HT few years back. They make a nice tight radius tubing,
not sure as tight as this effort, but maybe worth a look?

 

[cruiserpilot]

I used aluminum. 12HT on a 60 had to bring the inlet low and then straight up past the air cleaner. As you
can see the extension I needed to clear the motor. That's the inlet flange there. The tight 180 is pretty tight.
Suggest SS to be honest. Make sure you clean out the inside once you are done. Yellow painters tape holds tight and
just burns off as welding. Kinda handy. Hope this helps you a bit.

 

[nab856]

I used VIBRANT tubing for my FMIC on my 12HT few years back. They make a nice tight radius tubing,
not sure as tight as this effort, but maybe worth a look?

A great suggestion! Buying the tubing bends commercially would eliminate much of the build time. We are working on air tubing for two intercoolers. One intercooler will be used for the turbo-supercharged engine. The other for just a turbo engine. The two turbo/exhaust side tubes and the intercooler-to-supercharger tube can be done with the tight radius bends from VIBRANT tubing. However, the intercooler to throttle body tube for the turbo engine has very little space. In this area there is a throttle position sensor and a coolant pipe that the aluminum tubing must work around. Fortunately, both the intercooler and upper intake plenum locations can be moved. After repositioning the intake and intercooler, all four tubes could be made with commercial bends.

 

[cruiserpilot]

On FB Whistle'n Soot is a vendor. His original 12HT inlet in SS was a twisted work of art but I had not hooked up
on FB at the time and only got pictures. His is definitely an older school engine guy. Worth a look.

 

[nab856]

I used aluminum. 12HT on a 60 had to bring the inlet low and then straight up past the air cleaner. As you
can see the extension I needed to clear the motor. That's the inlet flange there. The tight 180 is pretty tight.
Suggest SS to be honest. Make sure you clean out the inside once you are done. Yellow painters tape holds tight and
just burns off as welding. Kinda handy. Hope this helps you a bit.

View attachment 4192279View attachment 4192280

Thank you for providing the actual bend radius. Excellent information! The yellow painter's tape suggestion is handy. Any tips that make a project easier are always appreciated.

 

[cruiserpilot]

I'm pretty OCD. I usually draw everything to scale on graph paper. Measurements to fall back on. Keep the 3D pic
in my head. I cook a steak with a stopwatch, so read into that what you will.

 

[nab856]

Reconfiguring hoses so the intercooler will fit on top of the valve cover.

Found a bending procedure in this video on Youtube:
He is a Toyota guy!

Here is what we used. Some modification to make a bend further from the end.

 

[cruiserpilot]

Reconfiguring hoses so the intercooler will fit on top of the valve cover.
View attachment 4208042

Found a bending procedure in this video on Youtube:
He is a Toyota guy!
View attachment 4208043
Here is what we used. Some modification to make a bend further from the end.

I saw that. Need to get whatever that weirdassed wire spring he used but no idea where to get that. Looks like a plumbers thing

 

[nab856]

It's a spring tube bender set. Available from a variety of tool purveyors.

$50. Really? It takes longer to boil the water than bending the rubber hose.

 

[cruiserpilot]

It's a spring tube bender set. Available from a variety of tool purveyors.
View attachment 4215168
$50. Really? It takes longer to boil the water than bending the rubber

Thanks for the name! Spring Tube Bender. If I’d only known. I’ll find one now and put it to work! Wicked cool!