moso wrote:Im not sure im picking up what your putting down
I was thinking of locating the core like this.
Nothing is to scale, and the core will need to be at an angle to keep from having a right angle and oval ports at the out plenum.
Finally had some free time to start hacking the old plenums off this cooler, and WOW did I underestimate the build quality of this little Chinese cooler. The damn plenum wall was a .250" thick in some places...my little Harbor Freight Cut Off Saw couldn't handle the pressure and gave up the ghost. I think it just overheated, but I finished the task by hand with my trusty Dewalt Angle Grinder
GREATEST TOOL EVER. Its like the Ice Cold Beer of the tool world...makes everything all better.
I also had to take a first aid break when a hot shard of Aluminium found its way past my safety glasses into my eye...likely I used to be an EMT and had sterile eyewash...a trip to the ER would a ruined the night.
Heres some progress pics.
A perfectly good intercooler...
It almost cost the sight in my left eye...
View of the business end of the core - pleease excuse the roughness, I wanted to be sure not to nick the core and cut the entire thing essentially by hand with the angle grinder. I am going to smooth out the cut with a bench grinder and leave plenty of space for welding without affecting the core.
I need to make the welding jig this week, chop the other side and start mocking up the new plenum. Things are going much slow than originally planned, but I am in no rush to f*** this up.
Another view of the business end through the SC adapter plate...
I also checked with Xcessive, and I can buy just the upper section of their manifold to try and simplify the fab. Not sure If I want to incur the extra cost, but its an option for others out there that may be thinking of a similar project.