All you guys that made your own intercooler piping, how do you cut the pipe? And do you have any pointers on the fitment process?

I know I'm on my own because I'm doing a custom job but I'd hate to make avoidable mistakes.

I wish I could just by an off the shelf kit, and would be happy to pay 1200 dollars for something well thought out, and quality, but I'm installing this with a 13b-re so unfortunatly it can't be off the shelf.

Oh yeah, I have a pretty good garage full of tools, and am pretty good with fabrication, such as exhausts and the like.

I'm going to be doing the welding with a 120 amp mig setup, with argon.

Is that enough to weld the intercooler piping?


If anyone has any advice please offer it up,

Thanks...

 

want to use aluminum pipe? you need tig :/

 

Not true. Aluminium can be MIG welded if you welder will handle it. You need a good liner (teflon) and you have to upsize the contact tip one size larger then the wire. Keep the cable to the gun straight to avoid jamming or use a spoolgun if you have access. You'll need to run pure argon and it takes some practice.

You can stick weld ALU as well but that's murder on thin metal. Gas welding works with the appropriate flux and rod but takes lots of practice.

As for cutting, I generally just use a cutting wheel. Fitment is usually trial and error. I cut conservativly, fit, cut, fit, cut and then finallly mark the orientation or tack it into place in the car.