Customizing an intercooler?
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Senior User
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From: Wisconsin
Customizing an intercooler?
So I was wondering, if i bought the 6.0L intercooler and wanted aluminum end tanks, is there any reason I can't remove the plastic and weld on some custom fabbed aluminum tanks? It appears that the tanks on the 7.3L coolers are welded on. Mainly asking because not sure how the core is assembled to the endplates that I would be welding to, if the heat from welding would cause any damage. I don't know if the tubes are crimped or soldered or welded to the endplates? Obviously if they were soldered the heat from welding would melt out any previous soldered connections. Any thoughts?
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Senior User
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From: Wisconsin
Well I'm planning a modded H2E with 238 hybrids, so I'm guessing boost will be around 40 psi give or take. The plastic tanks may work but I always like to do things better and I'm not afraid of the welding.
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that'd certainly make it worth it. i know it can be a pain to weld on aluminum radiators, the heat can collapse the coolant passages and the heat cycles can make them more brittle. lessons learned on a demo car. ICs are designed for more pressure than a radiator, but logic tells me you'd need to be careful.
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From: Wisconsin
Yeah I was wondering if there would be any ill effects to the cooler by the welding heat. I know the tanks are welded onto the 7.3 intercoolers, so I would figure it can be done. If I did it I would tig weld the aluminum.
Elder User
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you'd have better luck with tig i'd imagine. we were using flux core mix, not exactly the best choice. you'll be able to control it a lot better with tig
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Elder User
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From: Olympia, WA
Go do some reading in the SD and 6.0 sections and see what kind of boost those guys are making with plastic tank IC's. Only the early 7.3 IC's were aluminum, the later ones are plastic tanks just like the 6.0 IC's. IC failures due to high boost are often mentioned but rarely actually reported.
Post Fiend
Joined: Mar 2007
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From: Johnson City, TN.
I run a moddedd H2e with 180 singles. I hit 40 and have no problem. I read somewhere that these will withstand quite a lot of pressure. Something like 60 or 65. I don't have proof just memory.
I have often wondered if we could take two cores and make a double size cooler. Now that would be effective!
I have often wondered if we could take two cores and make a double size cooler. Now that would be effective!
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From: Wisconsin
Although, I'm not sure where you'd find the room to install that thick of a cooler on the truck...
Post Fiend
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From: Texas
If you don't mind trimming the hood a little and maybe a couple of other minor modifications
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