Pictures of the Week August 22, 2002
These are pictures of the left end cap being welded to the intercooler core. This is a big deal for me because the intercooler core cost $150 and I can't afford to replace it if I mess it up. Welding on the core was quite anticlimactic. All of the difficult angles and curves were on the end caps. The core was four straight welds. Weld down the side, rotate the core 90 degrees, weld across the end, rotate 90 degrees, weld down the side, rotate 90 degrees, and weld across the end. The simplest part is welding straight lines.
For now I've run out of welding rod and my supplier will not have my next shipment to me till Monday. I'll fit up the right end cap and exit pipe this weekend and be ready to weld it together on Monday.
The last picture is the right end cap being constructed. I use 3" aluminum tube cut in half. Then I put a 1" bevel on the end and weld on an end plate cut out of .080" aluminum sheet. I tack weld it on the inside and then turn it over and weld the seem around the edge.