A large shipment of 3.5" aluminum tubing arrived from Frozen Boost, it's the cheapest aluminum 16 gauge pipe we could find. Time to get started on the heavy plumbing and cooler fabrication:
The next step was getting an intercooler large enough to handle the flow of (2) S475's or roughly 200 lbs per minute or 3000+/- CFM. Todd had (2) old and lightly used Frozen Boost water/air coolers sitting on the shelf so keeping true to the theme, it was time to merge them into something useful.
The first step was to open them up using a 4.5" hand grinder with a cutting wheel (no access to a band saw).
Todd is still new to TIG welding aluminum but slowly getting better:
In case you haven't picked up the concept from the pictures, each separate S475 will blow compressed air into one of the outer inlet tubes, the boost will flow across the two coolers and merge into the center outlet pipe. Intercooling between stages is important on this build for (2) reasons: it aids in overall system efficiency by increasing charge air density prior to the second stage of compression & it decreases the thermal fatigue load on the GTX's compressor wheel which could overheat and fail if ran hard while being fed 350+ degree charge air vs. 120-130 degree charge air it will receive thanks to intercooling.
Due to the potential high boost these coolers will receive, some additional bracing was added to reinforce the merged cooler connection.
V-bands were also added to prevent blown charge air cooler boots/hoses.
All finished: