What's An Intercooler
its a v2 intake. it was made years ago. im sure someone has one around.
Not yet.. we're finishing up his headers now.. I should have some more pictures of those today. Im very happy with how they're shaping up. We should be back on that intake next week. Im one v-band short of being able to finish his headers so I have to order another one.. but the hard work for the headers is done.anything new wit this? :smile:
So you put me in line for one? You know you want this intake on one of the fastest hotair cars right it will be the fastest next time out. I have a few ideas on the intake as well to help. Pm me if you wantmore:
Let me describe for you what goes into fabricating one of these.
First, set it up in a Bridgeport, to cut it open the right way. The Bridgeport (mine is really an Enco) is a 3 phase machine, 3 HP. So I have to turn on a 5HP 3 phase converter, it uses a lot of electricity. Set up takes about 30 minutes, and it takes at least an hour to an hour and a half to cut the intake out.
Next, I weld the two ports to allow room to equalize them, weld the narrow section at the inlet to widen it, and then weld plates in the two fake ports inside. A TIG welder requires electricity, water (cooling tower), Argon, Tungsten electrodes, and filler rod. This welding takes over an hour.
Next, back to the mill, where we make the roof of the plenum, out of 5052 aluminum plate. Then we widen the narrow section of the inlet. Takes an hour or so, plus setup time.
Next, back to the welder, to put in the plenum roof. About a half hour or so.
Back to the mill, to do the heavy part of blending the plenum roof.
Half an hour.
Then, off to the porting bench. Now we port and polish the actual ports, and finish blending the plenum roof. This takes 4-6 hours.
Now, we move to the flow bench, has a 10 HP motor that drives a 6-71 blower, takes plenty of electricity, and is deafening, I can't hear the phone, or any customer who may walk in. We take a prefabbed basic plenum and attach it to the intake, and check the runners for flow. We allow +/- 5-7 cfm variance between all 6 runners. This takes well over two hours, closer to three.
Back at the porting bench, we bring any low ports up to meet the better ports, and all reach the flow level we expect. Takes an hour or so to get there.
Back to the flow bench to verify everything is correct so far. Another hour and a half minumum. Sometimes two and a half since here we go back and forth between the flow bench and the porting bench.
Now, after all that, we have to build the two side walls, the front wall, and the floor of the plenum.
First, back to the mill to cut out the basic pieces and rough them in. Takes an hour or so.
Over to the welder now. First, we make the front wall, I'll just tell you it is not a single flat piece, nor is it curved like the T-M version. We weld it together, and weld it in. The two side walls are fairly simple, we weld them in too. Then we shape and weld together the plenum floor, with the flow correcting "appendages".
We're here about three and a half hours, because the pieces have to fit just right, and it is very difficult to weld in a tight area on a piece of aluminum that will charr your flesh if you touch it.
Back to the porting bench to smooth and blend the front and side walls where they are welded in, and to finish the plenum floor so it can be welded in. An hour and a half at least.
Finally, back to the welder, we weld the plenum floor in. Takes over an hour, you can't rush any of this, warp it and it's junk.
Now we head over to a solvent tank to check for leaks, and back to the welder to repair them if required. Another hour.
And now, the flow bench again, to verify under pressure that there are no leaks. Then, we set up a test fixture to measure air flow and pressure at all six ports, to make sure we don't send out a problem. Setting up and measuring all of this takes three to four hours, due to the need to set up devices to measure with at all six ports, and to take and verify the readings at least twice.
Then we have to fabricate and weld on the lower cover so that hot oil stays off of the bottom of the plenum, and that those areas exposed by cutting the intake open are sealed off again as they should be. Two hours
All of that assumes that every step goes perfectly, or at least 90% error free. That's near 30 hours on an intake that goes very well, and I left out cleaning and stripping the intake, verifying that the intake itself is sound and solid, and needs no repairs to begin with. Nor does it count setting the intake up in a Storm Vulcan 85B and truing the flanges to assure that it bolts flat and perfect to the heads and block.