How to fix an intercooler??

carcrafter22

carcrafter22

New member
Joined
Oct 24, 2007
Messages
1,139
So I was in the shop today installing the new a/c system for my project specificly the condenser. I was drilling the final hole to mount it up when the g/f comes over and wants to show me something (actually a pair of somethings.:bang) and stole my attention for just a second when all of a sudden I punch through the core support and right into an intercooler tube. The hole is about the size of a dull #2 pencil tip so its not that big but it needs to be fixed. The intercooler is from a 2005 and has the plastic end caps if that matters.

I was wondering if anyone knows of a cheap fix just to get me by for a little while till I can upgrade in a month or so. I did take the twins off temporarily so max boost I see will be 25-30psi. jb weld? solder? Lets hear the ideas.
 
If you can reach both sides of it and it's temporary I'd just stick a bolt through the hole with some silicone around it and put a nut on to hold it tight.
 
Pop rivet with a little silicone? ..... Oh wait, then you put that dang break-off ball into the intake tract.


I'd just rough it up with sand paper and use a dap of silicone with a little piece of screen or mesh pushed into it for more strength.

JB weld will work fine for a month or two as well.
 
HAHA I would post pics but I would probably get banned and said pic would be deleted. Sorry guys LMAO!!

I think I will try a small dab of JB weld and let it sit overnight, I would imagine if I get enough in there to soak into the fins it should be pretty strong and last a month or two.
 
I knocked a hole in mine and just sanded and jb welded and it's held for 3 months and i see 60 + psi daily. Ialso have a good i/c w/ plastic ends u can have if u pay shipping.Let me know,i almost threw it away today.
 
Make sure you always have a pair of ratchet straps along with you so you can fix the intercooler once you blow the end caps off..lol

Mine has never seen what I would consider high boost numbers, may 30-35lbs. Blew one side off on the way to TS, thankfully Garmon and Swole helped me out with the strap idea and a spare cooler.

I would certainly look into a stock metal cooler at a minimum, I picked one up for $150.

Good luck with everything. ROB
 
Rbell, thats the plan eventually, I just have so much other stuff to do, I still have to weld up all the seems on the old truck, that will probably take a few days easily (trying not to cause too much warpage). so far the stock plastic cooler has seen well over 60psi (pegged the gauge several times) and was still going fine till the drill bit came along lol
 
You must log in or register to reply here.
Back
Top