Intercooler Construction

[86LaserXE-XT]

just curious how most alluminum intercoolers are put together.
I know the endcaps on mine are welded on but how are the cores attached
are they soldered on like a radiator? or are they also welded. seems like alot of welding around all them cores.
kinda hoping I can desolder the cores and cut them down to shorten my intercooler by 8"
either that or I sell my intercooler for the scrap alluminum and go buy one from a powerstroke ford.

thanks for any info.

-Jason

[Paradox]

tube and fin ones are prolly soldered but double check with someone who has torn one apart first.

[86LaserXE-XT]

Upon Closer inspection of my intercooler it seems the cores are welded
thinking it'll be easier to just order a intercooler off E-bay than to try and cut my MONSTER down. and I can sell the one i have for 50lbs of scrap alluminum lol. or make a table out of it

[Paradox]

want a alum. G head for it if you just scrap it?

[kermit]

That must be a semi truck intercooler. That thing is is probably bigger than the front of my car!!

[Gutfeeling]

I say make it a top mount... Since that'll be the only place to put it!

[86LaserXE-XT]

I had considered that since it's about the size of the hood on my minivan lol.
and yes it's a semi truck intercooler a western star that had hit a moose
the intercooler is bent back about a half inch on one corner.
I could make it fit in my van on the front if I cut my headlights down and make new mounts for the bumper and new endcaps for the IC and cut the top of the radiator support and hood latch out. lol
the core alone is 36"x24" with the endcaps on the IC it measures in at 48" wide by 11" deep. and it weighs a healthy 50 pounds.
as far as trading for a G head, sure I could use a G head but I live in alaska, so the shipping wouldn't be pretty.
oh well it'll make an interesting table

[86LaserXE-XT]

oh forgot to add this picture,

think it'll fit? lol

[xtrempickup]

will fit with a little cutting perfectly

[86LaserXE-XT]

if only I had a Gas Wirefeed Welder to modify this thing to fit my needs.
I've got no problem cutting the back off the headlights and rewelding the plastic together to clear the IC and modifying the bumpers, I plan on getting the ABS plastic bumper covers anyhow and I'm sure I can make some kind of mount for them.
and the hoodlatch removal isn't a problem I can install some Ricer hoodpins lol
but without the ability to weld the aluminum I can't install it with the connections it has.
I've found the 4" to 3" adaptors. problem is they go through right where the part of the frame meets the radiator support and then they'd go so far in they would hit the trans and the pulleys on the engine lol. oh well. I can buy a $100 cheapie IC from E-bay and use this for an excessive paperweight lol

[Paradox]

ouch 50lbs is allot from Alaska

[86LaserXE-XT]

Zip is 99645 if you care to check shipping at USPS.com
over 48"x36"x4" would be the size lol.

edit... I said 4" but actually with the connections it would be over 11"