TFS: How to Build Custom Intercooler Piping

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Custom intercooler piping can be very tricky to manage because there are literally thousands of ways to run and route the system. In this special segment of #TFSBoostFab, Justin the Fabricator demonstrates the simplified method for fabricating a custom intercooler piping assembly on an Evo 8.
TFS Boost Fab is a special segment related to the automotive performance fabrication industry. Make sure you check out the other TFS Boost Fab episodes for more!
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Опубликовано:

21 ноя 2016

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Комментарии : 295

@benabusthethird9751 5 лет назад

Honestly.. Thank you for noise warnings.. I'd also just like to chime in and say thanks for the little bits of wisdom I'm learning from your videos. Appreciate everything you do. Thanks buddy

@matthewhart1767 15 дней назад

Thank you for the vid. I was a little stressed out about how to properly get this done, but after watching your vid, I was able to fab some custom pipes for my project and I was surprised at just how simple this was! Took a little bit of trial and error, but the methods shown in the video really helped me along in the process. Thanks a ton!!!

@craigdouglas8095 2 года назад

Straight to the point no nonsense information, great job thanks for sharing 👍

@TheCycle2300 3 года назад

Fantastic video. I've been wanting to add a centrifugal s/c and intercooler to my LS and this really helps show the proper way to get all the intercooler tubing done myself.

@russverbael2089 6 лет назад

This series is the BEST. Well presented, great photography, Justin is a super capable fab'r and excellent speaker. Thanks.

@WigglingWaffles Год назад

made my own custom intercooler pipes in a weekend using only this video as reference. very well done guide, it really made the whole job less daunting. I never would have thought to cut an angle in half to dodge other parts and was able to clear my sway bar so much better than if i had not known that trick. boost leaks begone

@daazndood 3 года назад

woah this was really cool to watch. Very interesting seeing it all come together!

@Norfolk440 4 года назад

Man I learned SO MUCH from this video. Thank you!!

@zoottoolie8568 5 лет назад

Noise alerts are life savers, keep up the good work subbed

@markrich3271 5 лет назад

The Fabrication Series I would love to see some intercoolers cores welded together for those really large custom jobs.

@tigquisiawelds3582 5 лет назад

All the time i see your videos i learn something new..thanks Justin!

@failranch9542 6 лет назад

Holy crap this is a good series!

@robhunter2435 4 года назад

Rivets or not that intercooler piping build is mechanical art...just beautiful. Its a skill I wish I had. If that were my car I would not complain about the rivets. I think it looks pretty nice with the aluminum piping. Good job!

@jeromeriaubia9224 5 лет назад

I have sifted through over 100 turbo "build" videos. Most are 95% uneducational. This is the 1st one that shows hands on fabrication throughout the whole video. I learned more in 20 minutes than hours of other videos.

@binstrap7612 6 лет назад

Great videos, thanks Justin!

@TrojanHorse1959 5 лет назад

Great video, very informative!

@7sins979 3 года назад

enjoying the automotive fab work while looking for a tig welder.

@CrazyDuner 7 лет назад

I use PET tape for powder coating. It's GREAT stuff and like Justin said, it can withstand pretty high temps and leaves no residue which is very important for powder coating. Thanks for the videos!

@TheFabricatorSeries 7 лет назад

I love the stuff so much that I sell it on my website haha. Thanks for watching!

@SlowEarl1 7 лет назад

Looks Great! Thanks for making video.

@TheFabricatorSeries 7 лет назад

Thanks for watching!

@OlisGarage 11 месяцев назад

Phenomenal video. Thank you!

@digitalbilly Год назад

great video well explained. learning lots thanks!!!

@AugustGunsZERO 7 лет назад

I'm glad I stumbled onto your channel. It's pretty useful for my eagle talon build. I've only got 300 in the thing and that's because i had to buy injectors and fluids. everything else i've built by hand on it. so i've already made like idk 8 feet of intake for it out of scrap for free. Thanks man

@TheFabricatorSeries 7 лет назад

Right on.

@amaterasu8829 5 лет назад

Justin is like the Bob Ross of custom instillation videos

@fastsofaracing 7 лет назад

Once again nice and informative video. keep it up.

@TheFabricatorSeries 7 лет назад

Thanks!

@renerostohar 3 года назад

Nice video, again a lot learing in it. Top...TFS

@MussaKZN 4 года назад

Good video bro Aussie boilermaker fabricator here doing coolers, plumbing and off road snorkel for ages. It’s funny to see even though were thousands of miles apart fabrication is fabrication “yer that’s were I’m cutting it that looks right there, tack tack perfect! I don’t tag my stuff but I would go a thicker tag and weld it, Unless your using captive mandrel I would have kittens thinking the internal rivet shaft could end up in the engine!

@Jayhl217 7 лет назад

Keep the videos coming bro!

@TheFabricatorSeries 7 лет назад

More on the way up to the tube now!

@anthonyarnold2499 4 года назад

Great work and you have helped this newb on welding aluminum. I enjoy learning, as we all do, on new ways to tackle these jobs. Keep the vids coming...

@TTTexMMMexBBBand 2 года назад

hello Justin. This is Javier. i just wanted make a statement that you are AMAZING.

@johnhenry6822 5 лет назад

Great video! Inspired to work on mine now. Though it may take years to do what you did in this video lol.

@chrispearson2663 7 лет назад

89mirageman here from mirageforums. Been watching all of your videos and I am impressed. I've picked up quite a few tips.

@TheFabricatorSeries 7 лет назад

Chris Pearson Hey what's up!? There's a few MPF guys floating around here. Always cool to see some familiar names. Thanks for watching!

@Stangnotch03 5 лет назад

Kickass work, just got a subscriber

@bartszwarc5433 7 лет назад

Great job, I like!!! Thanks

@TheFabricatorSeries 7 лет назад

Thanks for watching!

@jimmyherring4349 4 года назад

Great job

@steveguest8028 2 года назад

This is a great video 👍

@ClimptonDiddlehopper 7 лет назад

I have used a small inexpensive (harbor freight) bead roller to put the slip ring on straight tubing before. it really looks like a pro job for a minimal investment and you have another tool that works in other areas as well.

@TheFabricatorSeries 7 лет назад

I've had the same one for about 6 years. It's junk. It just sits on my shelf.

@olenairsoftguy88 4 года назад

great video!

@720engineering9 5 лет назад

Fantastic.

@terryleyendecker8934 5 лет назад

Thanks that was cool I do pip work to but to see someone else's tricks of the triad helps wasn't to long or over explained nice job o what kind of tape is that didn't realy explain much about it love to see more helpful tips AWESOME VID

@matthiascross5212 3 года назад

Good video man

@coryhalvorson8874 4 года назад

man, 4 years later and I'm coming back for a refresh now that I have a tig welder... and people are still getting mad at the rivets xD you could take the BOV out, have that 1 7/8" hole open to atmosphere and still build boost.

@anakinskypooper5581 3 года назад

I appreciate u bro big time

@johngalletta9379 3 года назад

I'm getting ready build twin turbo on a 2006 dodge magnum srt8 6.1 hemi. I learn alot here

@stevebarnes9694 9 дней назад

When you do brackets to reduce movement....where do you try to go to and what material do you use.. GREAT video. Thanks

@nelagordon24 3 года назад

I wish I had a shop jack/lift :(

@Mitutumuch 3 года назад

all do brody

@buckshot927tx 3 года назад

Don’t let that stop ya brotha.

@jonothatsright3231 5 лет назад

Awesome vid man, how do you find the ebay cooler pipe when welding it up? I noticed you didnt back purge i this was a bit of a must do when dealing with elements such as air especially going into the engine? As in the flakey crust stuff that can chip off on the inside of the pipe or do you run a rag/pad etc thru the inside too? Cheers

@WillRobinsonDanger Год назад

BEAUTIFUL!!!!!!!!! I would mind finding you to build me one for my Saab 9-3!!!!!

@weldingjunkie 6 лет назад

Awesome video I love this and your exhaust work. Could you of used v bands?

@TheFabricatorSeries 6 лет назад

I could have.

@HollywoodMGB3 5 лет назад

Great work!! Where did you have your name tag made?

@dcstang67 7 лет назад

Another very informative video. Great job! I actually figured out to use the pet tape on my own about a year ago when welding up some pipes. I had a roll of that tape for doing powdercoating and i figured it would work really well for the welding. Im glad to see someone else doing the same thing with it. On a side note, you forgot to mention the most important part of cleaning out the pipes before final install. What method do you use for getting all the chips and oils out of the pipes?

@TheFabricatorSeries 7 лет назад

dcstang67 I order the tubes already cleaned and polished. All I have to do is cut and weld. There's almost never anything remaining inside when finished.

@dougmarthaler3066 3 года назад

How much flexibility do you typically allow in the piping for engine movement vs the solid mounted cooler? Any “rule of thumb” recommendations? (Couplers, etc?)

@Lords_Of_Ring 4 года назад

Cool tutorial. I was going to ask why not weld on the tags, but found the answer in other comments.

@ojay4159 6 лет назад

Fantastic job!!! I just subbed your channel...But why didn't you tig your brand logo onto the top pipe?

@adrianm5147 4 года назад

Is there any particular place you recommend for parts and materials when building intakes and exhausts?

@thyresias194 7 лет назад

Good job bro, see you next épisode ;-)

@TheFabricatorSeries 7 лет назад

Thanks! Two more are coming up very soon. Thanks for watching!

@nycyabber7103 7 месяцев назад

This video made me 100% confident in the fact that I need to bring my car to the shop 😂

@alexzepeda9034 4 года назад

Can you please post a link of where you bought the pre made bends for the piping? I’d like to purchase a few of those! Thanks!

@thehappytexan 5 лет назад

Like the kiss approach. My ocd brain wouldn’t worry about the rivets leaking boost, I wouldn’t do it for the “what if” factor of them failing under severe heat cycling and going through the engine. After being a heavy duty diesel mechanic for 15 years, you see some pretty crazy failure caused by $.50 parts. Lol.

@jeffreymoore4132 7 лет назад

Thanks for the great instruction video!

@TheFabricatorSeries 7 лет назад

Thanks for watching!

@luciandickens2418 4 года назад

Awesome

@mikejohle3717 4 года назад

I love your work my friend , but if you have a customer that ever runs methanol injection, it will find it’s way into those those rivets and corrode them. I know it’s injected at the throttle body, but it’s corrosive as hell and I’ve seen the vapors do this over time, please tack weld those because your quality it is amazing

@muchoos 4 года назад

Thanks about noise alert : )

@jamiethomas4716 4 года назад

Time to get out the powertig and attempt to do this!

@robertragland6084 Год назад

I wish someone like him lived in my area...im tired of dealing with these shops who cannot fabricate anything!

@nitrodon7184 6 лет назад

Great video! I like the Intro very much. How is that song called?

@jameslames1630 7 лет назад

Great video as always. Is there any negative affect of welding the tag on?

@TheFabricatorSeries 7 лет назад

James Lames There is no negative affect to welding it.

@EtherFox 7 лет назад

Thanks as always. Also, at 6:00ish, you mean vertical (which is, notably, perpendicular to the ground); no matter which direction you clock it, a 90 degree bend mounted/cut straight on will be perpendicular to tube you are welding it to 'cuz geometry.

@EtherFox 7 лет назад

This is to say, you were saying you DON'T want to make everything vertical. Unless you did some pie-cut kinda trickery, the 90 degree piece *will* be perpendicular.

@TheFabricatorSeries 7 лет назад

Valid point, but I'm pretty sure it was understood.

@aaronwowzree 7 лет назад

Very cool. I'm surprised you don't have a bead roller. There are a few ways to make you own bead forming tool using pliers. I'd love to see your take on it!

@TheFabricatorSeries 7 лет назад

Aaron Wolff I know there are a few DIY tools and such, but I just don't need one.

@georgedicker9789 Год назад

Thanks for this video man, amazing stuff. Did you not have to roll the end of the pipes? I made some pipes up my self before and after a couple of weeks of some full boost every now and then it popped off the pipe

@elmeradams8781 Год назад

I've heard of people putting a weld bead on the end of they don't have the tool to roll it.

@ronielcrewe1277 Год назад

could you do a vid on the saw did you use a speed reducer on it

@ThePitbull30 7 лет назад

Hey man.. Great content as always.. I think riveting on your tag isn't such a great idea.. But hey keep em coming.. Love ur vidz man

@TheFabricatorSeries 7 лет назад

ThePitbull30 Trust me, there is nothing wrong with rivets. It's been done for years and it will hold for ever.

@HoustonMetroRecovery 4 года назад

Riveting isnt an issue whatsoever. Anyone who thinks a 1/16" hole that's filled with the actual rivet will make a difference needs to stop commenting on turbo builds. Keep up the good work!

@eduardodaquiljr9637 Год назад

Would it be possible to adopt intercooler for non-intercooled turbo engine?Example is the case of Delica Starwagon turbo.

@deanvandeventer6186 6 месяцев назад

I have a 2260 turbo on my 1.9 seat with a 63mm hot side charge pipe and cold side 76mm but it take a long time for it to boost what size should I fit to make it boost quicker

@3dbarn547 8 месяцев назад

I did exactly what he said not to do. Built my whole kit without having my rad installed and yep I dropped the radiator down and added a remote fill and relocated the sway bar because of it lol.

@dreamfpv7865 4 года назад

Arrh man I loved it until the rivets 😵 Come on man 😆

@ericxiong6582 4 года назад

2 tack welds on each end would have suffice...lol

@shawne7225 4 года назад

you know they put rivets on aluminum boats 😵😆

@brooks3racing1 4 года назад

shawn e water is a bit more viscous than air, and boost leaks cause havoc with a tune.

@bax442 4 года назад

@@brooks3racing1 Rivots do break off. Imagine the piece of aluminium causing damage to the engine and then the cat.

@ubbynubb 4 года назад

@@shawne7225 imagine having engineered holes in your boat

@s123fro 2 года назад

What could you use to knock down any welding debris on the inside of the piping? Say it was more towards the middle and you couldn't reach it to sand it down

@2slofouru 6 лет назад

I wish there were someone who took as much care building the piping as you, would be nice to get my subie piping custom to be able to maximize fit and minimize the number of couplings. I don't want another crappy fitting ebay kit that still has to be cut anyway.

@velocityshopsales7478 6 лет назад

You would make one hell of an audio book narrator.

@grayhound1993 2 года назад

Do you have a part number on that DeWalt blade?

@all.for.snowmobile 6 лет назад

Do you make an intake pipe, and fix a shilda with holes, on rivets? Is not it better to weld!

@dzionassi 4 года назад

Could you please tell me what size tungsten was used and what amp setting? Just bough my first tig, trying to make custom intake... Not going well...

@michaelangel7448 7 лет назад

hey man nice work . when you're doing a custom job, do the placement of the box matter if it's on the cold side of the intercooler pipe or the hot side

@TheFabricatorSeries 7 лет назад

Michael Angel There will always be an argument regarding hot side vs cold side haha. It's most commonly found on the cold side, but it doesn't matter where you put it at the end of the day.

@michaelangel7448 7 лет назад

Thanks man

@BulliKid 3 года назад

So where does buy the metal for all this?

@CarlosMontalvoGhigliotty 5 лет назад

Justin what carbide blade is on the chop saw and diameter?

@Aflikted0985 3 года назад

What does the MP stand for on your tag?

@jonjetleewayne1939 3 года назад

What welder settings slash filler rod do you use

@maximchu5813 6 лет назад

Hi! what is the model name of your DeWalt saw? I would like to buy it.

@benznut7006 5 лет назад

great video, wondering why you didn't purge the inside?

@TheFabricatorSeries 5 лет назад

Aluminum is not a reactive metal. It does not require back purging and there is no benefit.

@michaelross6281 3 года назад

id like to see those welds ground down, and the pipes polished so it looks like one piece.

@kingboy19971 2 года назад

Where do you get your metal piping from?

@timeslipmotorsports Год назад

What do you do when transitioning your 180⁰ and the cut ends are not completely circle (the outside edge is a little more flat then the inside of the 180)

@dresdensvo 7 лет назад

What is your tungsten and welder settings for intercooler tubing? Cut deburr and weld , is there more prep off camera?

@operatesmoothly 7 лет назад

Gtperformance Dresden +1 for welder settings. mostly ac balance and freq. and power source?

@TheFabricatorSeries 7 лет назад

There is no additional prep than what is seen. Cut - clean - weld. I usually use 1/16" tungsten on this thin stuff and I taper down in amperage with my pedal starting around 85 amps or so (I can't look at the dial while welding). Balance and freq. are automatic on my machine so I have no control over them.

@dresdensvo 7 лет назад

Just trying to improve my results on the same tubing.using a miller diversion 165 { only get to control amps} with mixed results.

@TheFabricatorSeries 7 лет назад

Just practice. Dont be afraid to throw some amperage at it and run the pedal to your advantage. When welding, you are basically looking to time your dabs to a split second between the moment where the aluminum gets shiny and the moment that is starts to fall out. The higher the amperage - the faster it happens, but also the less control over the puddle you end up with. You can start high on the amperage while the metal is cold and slowly back the amperage off as you progress. It just takes some practice.

@weldingjunkie 6 лет назад

Gtperformance Dresden step on pedal until it puddles and then more or less than and go from there. That’s a tough machine for aluminum with no adjustments.

@J2GXP 7 лет назад

Great video! Where do you get your intercooler pipping from?

@TheFabricatorSeries 7 лет назад

I order through a vendor (wholesale). You can usually source good deals online through trusted vendors. Just try to avoid bargain deals. We call those materials "mystery metal" because it will claim something like 6061, but welds more like cast.

@J2GXP 7 лет назад

The Fabrication Series - Can you suggest any good vendors?

@nospherat666 6 лет назад

I call it Chineseium :))

@idriwzrd 7 лет назад

Great video, as always. But I wonder, why rivet the tag rather than a few tack welds?

@TheFabricatorSeries 7 лет назад

It a very difficult weld to make. The tag usually burns away before the tube gets hot enough to get a dab on it.

@matthewlefaivre2111 7 лет назад

How thick are the tags? Try starting the arc on the tube and slowly move your way over to the tag. If you are melting the tag corner away you are burning too hot. Just make sure you start to get the tube to puddle, add some filler and move over to the tag. Its quite simple. The tags I use are .125 and I don't even use filler and just tack the corners. The above method works great for it.

@TheFabricatorSeries 7 лет назад

Matthew Lefaivre I've tried every method I know with this welder (which has limited control) and nothing really works. the tags are .065. If they were thicker, I'd have no problem. Haven't had one bend or distort yet, but it would be extremely simple to replace on if it ever did since I use rivets.

@rayschrum5855 7 лет назад

Matthew Lefaivre of

@matthewlefaivre2111 7 лет назад

What?

@yvestheunissen 4 года назад

Is back purging not needed for aluminum intercooler piping?

@StevenDec13 7 лет назад

Great video!!!! where are you located and do you have a way that I can contact you?

@TheFabricatorSeries 7 лет назад

I am in Las Vegas, NV. Any one of the social media outlets or www.TheFabricationSeries.com website has all my contact info on it.

@jonjetleewayne1939 3 года назад

I build exhaust for a living I could cut pies and bend pipe is I have too but never really welded aluminum only stainless or aluminized exhaust tubing

@greg925911 5 лет назад

could one use V Claps to connect the pieces

@starang180 4 года назад

Late to see this video and comment...but could you reply about the saw you are using?

@southsidestunts5472 7 лет назад

how long did it take you to learn how to tig weld? i do stick and mig welding but im really wanting to learn how to tig. any tips?

@TheFabricatorSeries 7 лет назад

I had it down pretty quick but I put in a ton of practice. Practice and patience is the best advice I can give. Also understand that videos and references are only guidelines and not necessarily the exact answer. It's mostly based on you and your preferences. A quick example of that is how I weld aluminum. I ramp my amperage way up in the beginning and taper down as I weld. Some welders prefer one steady amperage, and some prefer to pulse. There are many ways to achieve the same result and learning that is probably the biggest battle.