I fabricated my intercooler inlet pipe out of 2.75" aluminum pipe. I got it welded up last night so that the pipe fits in between my single turbo and the intercooler (I kept the airpump). I opened up the blow off valve box (tial 50mm) and realized that the flange they sent me was mild steel. In addition to it being a different material, the flange appears to be shaped for a smaller diameter pipe.

It is hard to describe, but the points of the flange that should wrap the pipe contour instead hit the pipe and leave gaps on both sides.


Here are my questions. Can the mild steel flange be welded to the aluminum pipe? Or do I need an aluminum flange? What do I need to do to get the flange to better form to the contour of the pipe? Should I grind it down?


Any help is appreciated...

Brian

 

You must get an aluminum flange. As the welding shop told me once, "if I could weld steel to aluminum, I wouldn't be working here, I'd be living on my private island" .

Flanges are usually set up for about 2.25-2.5" pipe. If it doesn't fit the pipe well, the flange would have to be ground until it does, which shouldn't be hard.

I know Tial does have aluminum flanges - shouldn't be a big deal there.

Dale

 

The AL flange is $50 worth of a deal from turbotrix...next dayed to me...

I knew there was no way...I was just looking for verification. The AL flange will be much easier to grind down too. Although I should have just gone with mild steel intercooler piping because I am powdercoating in black when it is finished, anyway...