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Intercooler Series: Derek at SpeedFactory builds Dual Core Intcercooler Pt.2

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Welcome back to part 2 of our Intercooler Series with Derek at SpeedFactory.  We are now going to be mocking, measuring, and cutting the materials for the intercooler in this portion.  We also will show you another piece or 2 in this article we made from scratch and detail why these components were needed.

 

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PART 2 – FABRICATE AND BURN

Back in part 1, we explained to you why it is crucial to have all of your fabrication components before you start your job, while giving a few photos of what we were using.  Our shopping cart tells you the exact materials we were using for the intercooler project and give you an idea of the outlets you will have to visit for these materials.  Vibrant Performance is a similar outlet, where you can go for all of your fab materials you may need to complete such jobs.

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End Tank Design

Without trying to point out the obvious I’ll start by saying intercooler cores are square and air moves most efficiently through rounds.   My goal is to trick the airflow into thinking it is flowing through a round object by making that transition from square to round as smooth as possible.

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It may sound easy, it may look easy, but keep in mind it has to fit within a chassis where the turbo and cooling systems are already developed and in place.   A couple things on my mind while I am making this is having a solid structure,..i want to have as few welded seams as possible because the welded seam will always be the weakest link in a pressurized tank (also the reason I weld the tanks inside and out).  

 

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With that being said some fabricators who have mastered the english wheel, press brake, slip roll may look at my design thinking they could have done it in fewer pieces or made a smoother transition…this is where repeatability comes into play…if there were to an accident or unforeseen damage to the intercooler I have to be able to quickly repair or re produce this intercooler again.

 

Inner Velocity Stack

Speaking of airflow, I machined this square to round transition to further smooth the airflow and try to keep turbulence at a minimum and velocity at a maximum.   This is at the intercooler outlet leading into the 3.5″ charge piping leading to the throttle body.

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Stack finished and welded, ready to adorn the end tank and flow like a freight train! 

 

The finished Product

As for the end result of the tank, it’s what I felt would fit, and perform best for our 1000+whp application. 

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Inside Jokes

We spy a Smurf! 

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Here is an inside joke with Cole.  It’s Smurfette, because he calls the Vibrant Civic Si “Smurfy” obviously due to the blue colors used on the wrap.  This little caricature was to be Smurfette holding down her skirt due to the wind inside of the end tank.  This is a great play on the classic Marolyn Monroe scene from the 1955 film The Seven Year Itch, placing Monroe in a white dress which is now famed all over.  Good go Derek! 

 

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This intercooler, while many pieces have been shortened and cut for your viewing, is ready to produce the 1000+whp that it will take to rail the Civic past those previous 8.4x time slips.  Last year, we bested mid-8 second passes but now we will eclipse those times.  A new day is on the horizon for the SFWD Civic you have seen.

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Intercooler Series: Derek at SpeedFactory builds Dual Core Intcercooler Pt.1

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Ok, we bring you a large amount of extremely high quality fabrication photos and topics on our Facebook Fan page.  We have also been bringing you top notch articles and topics on Fabircationlife.com, including; Quickies: Intro to Tungsten & PrepSolidWorks TipsPrep Is EverythingFabricators Series: Collectors 101, and all of our Tig’d Up Tuesday reviews.  Now we want to show you a more detailed fab session with a seasoned vet, Derek Chorum.

 

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Tig’d Up Tuesday Review 2-18

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Before we give you this Tig’d Up Review, we are going to do a replay of a few previous Tig’d Up articles, showcasing previous work.

Tig’d Up Review 11-26-13

Tig’d Up Review 12-3-13

Tig’d Up Review 12-10-13

Tig’d Up Review Holiday Edition

Tig’d Up Review 12-31-13

Tig’d Up Review 1-7-14

Tig’d Up Review 1-14-14

Tig’d Up Review 1-21-14

Tig’d Up Review 1-28-14

Tig’d Up Review 2-4-14

Tig’d Up Review 2-11-14

 

This week, we had entries featuring Industrial, Exhaust Headers, Race Radiators, and Exhaust Systems. We tried to focus on complete parts rather than 1-10″ sections of welding. The idea was to have featured images that showcase finished products. We will be looking for that this week in our submissions as well. Good luck and submit early!

 

On to the Review!

David D./ D3 Performance Engineering

This thing is just sick! 321 stainless tri-Y turbo manifold all slip fit for a 2JZ with a ProMod 88mm turbo. Feature coming on this 240sx shortly on Fabricationlife.com, too…

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Tig’d Up Tuesday Review 2-11

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Your Tig’d Up Tuesday Review for the second week of February is here . We enjoyed another successful week of posts, and got a ton of submissions! Here they are:

Priit KukkFabrication

“This is a mic fastening point on a acoustic stand for exhaust gas analysis. Welded with a Kemppi MasterTig 4004 1,6mm 316 filler, pulse setup : 90 amp 40% duty 1hz frequency.”

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Nick Primero

“Tigging away on racecars this week.”

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Samuel Hoskins

“Here is some work from Ben Issacson, owner of Ground up Motorsports in Australia”

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Richard Rasmussen

“Thirsty?”

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Brandon Kalcsics

“Carbon to chromoly, running at 200amps. Freehand dab on a 77 honda cb750 hardtail.”

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Race Ready Fab

“Civic custom exhaust 304ss machine thermal arc 186″

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Derek at SpeedFactory

“Backdoor intercooler endtank with change.”

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Dane Reynolds

“304ss v band clamp by tig welded by Dane from RB Garage toowoomba”

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Keep the submissions flowing! See you on another Tig’d Up Review!

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Tig’d Up Tuesday review 2-4

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Tig’d Up Tuesday Review is a weekly playback of entries we chose to fill our Facebook Fan Page with. We have another great Tuesday up for review today. Things to remember when you are submitting:

  1. Please make sure you submit clear, sharp, crisp, and non-blurry photos.

  2. Make sure your photos are in focus. We want to highlight the weld or product you are showing off.

  3. Make sure you include your weld and machine information.

  4. If you submit and we feature, comment on the post. People will ask questions.

  5. If you are featured, please share the our post on your network. Show off your work.

 

Now let’s get to the review!

Chris Wilkes

“Steel welded with 70sd2 rod” Chris Wilkes Fabrications

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Tig’d Up Tuesday Review 1-28

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Another Tig’d Up Tuesday in the books! This one was perfect and tons of people visited the page. We want to thank everyone for the submissions. We chose a few to show a few completed parts this time, not just a few inches of welds.

Check out what we posted and tell us which one is your pick:

Tyler Timmel/The Arc Asylum

“Header jig I built this weekend”

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Matthew Owen

“Twin turbo lsx swapped Lexus is300. Sh10 manifolds single pass welded @ 90 amps 1/16 308 filler fully back purged with a miller dynasty 200 no pulse.”

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Scott at MoFab LLC

“Coolant tank for customers STI”

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Aldo D3 Performance Engineering

“Aluminum dime droppin! iPhone pic, no pulse or pedal pumping”

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Paul / Dezod Motorsports Inc

“Dimeage”

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Derek/Ricky at SpeedFactory

“Dual backdoor intercooler/tucked radiator combo. Features Vibrant Vanjen inlet/outlet connections, intercooler is flanged with a Tial 50mm BOV connection.”

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Collin ToxicFab.com

“321 stainless love on this freezing cold day.”

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David D3 Performance Engineering

“MAF flange weld , 3/32 tungsten, 1/16 rod, small collet, Miller Sync 300, no pedal, all metal”

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Tomorrow on Tig’d Up Tuesday we want to see all of your intake work. So if you have any manifolds, piping, and sensors send pics our way!

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Tig’d Up Tuesday Review 1-21

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This was one of our most packed Tig’d Up Tuesdays in a while. We numbers of submissions, and work from all industries sent in. We chose 10 this week, and the page saw traffic from across the globe!

 

As we said before, we will be featuring more than 10 entries every week now, so make sure you get your submissions in. If we do not use them, please keep sending. We may use one you send on a future post in the page.

 

Here are the submissions:

 

The Turbo Elements 

“Some drops with some dimes”

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