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My Water to Air intercooler install
- Thread starter n8in8or
- Start date
Husker6.5
135' diagonal 16:9HD, 25KW sound!
Looking good, Nate! Black and silver, how about polishing and buffing the hell out of it and shooting it with clearcoat?
n8in8or
I never met a project I didn’t like
Too many pinholes that I have decided to not fix...
n8in8or
I never met a project I didn’t like
Braces are made. I made the studs a little long on purpose so there will be enough thread for a washer and a nylock nut. Now it's time to remove the bumper and weld the pieces out. I think that is finally it for fab work. Time to finish things. 
n8in8or
I never met a project I didn’t like
I chronicled that in an earlier installment.....your oil lines are so strong that when I tried to move them to the side for clearance the oil cooler broke before the lines would budge!Hey! and what kind of engine oil cooler is that
n8in8or
I never met a project I didn’t like
Well I thought I was done. Took pictures and everything. Then I noticed a little dimple in one of the deflector pieces where the welded stud is. So I looked closer and saw a couple more dimples. So I cranked on the nuts and sure enough I was able to get them to pull through. GRRRR. So I pulled them all out. I tried chamfering the holes and grinding the studs to a point. Nope, that's failing too. So now I'm unsure what I'll do....just do some nice stainless button head bolts? Not sure, but it's hard to think after working on it for 6 hours and now being frustrated. So I'll have to let it sink in overnight......
n8in8or
I never met a project I didn’t like
Decided to do a quick mockup with some bolts I had lying around. 
ak diesel driver
6.5 driver
Looks good. Another alternative might be carriage bolts
n8in8or
I never met a project I didn’t like
Yeah I was thinking that too. I have another idea that might work, but it's kind of hard to explain, so I'll try to give it a go tomorrow and see how it works.
IMO go back to shaved smooth. It hurts my eyes now.
n8in8or
I never met a project I didn’t like
I agree. All this work and it should be smooth. I think I can do it still. We'll see....
Jaryd
Extremely Deplorable
I work with metal for a living and you made that look easy. I wish I had the patience you have when I'm working on my stuff around the farm or on my truck. Good looking bumper for real.
n8in8or
I never met a project I didn’t like
Thanks Jaryd! The hours and hours I've spent working on this thing sure haven't felt easy....
n8in8or
I never met a project I didn’t like
Ok I found a solution. If I had executed it properly it would have been a fantastic solution, but I struggled a little and had to do some rework.....but in the end it turned out ok.
First thing I did was drill out the holes to 15/16". And no....that didn't freak me out one bit.
Then I installed carriage bolts in the bumper braces. After that I installed the deflector over the bolts.
Next was welding. I was able to lay some nice beads since I had so much real estate to work with.
Then I ground the welds and bolt heads down.
After that I reinstalled the deflector. This is when I found out that I had screwed up earlier. I got dimples again!!! But I couldn't pull the bolts through like before...which made sense. What I did wrong is I had only finger tightened the nuts before, not wrench tightened. So when I reinstalled the deflector and tightened the nuts with a wrench it drew the bolts in a smidge and voila....dimples!
So I ground the deflector down to the height of the dimples and DAd it and now all is well. It can use a little more sanding, but I wanted to get it reinstalled to make sure it was ok before I took it to the nth degree.
So now I just have to do the same thing to te other deflector, sans screw-up of course.
First thing I did was drill out the holes to 15/16". And no....that didn't freak me out one bit
. Then I installed carriage bolts in the bumper braces. After that I installed the deflector over the bolts.
Next was welding. I was able to lay some nice beads since I had so much real estate to work with.
Then I ground the welds and bolt heads down.
After that I reinstalled the deflector. This is when I found out that I had screwed up earlier. I got dimples again!!! But I couldn't pull the bolts through like before...which made sense. What I did wrong is I had only finger tightened the nuts before, not wrench tightened. So when I reinstalled the deflector and tightened the nuts with a wrench it drew the bolts in a smidge and voila....dimples!
So I ground the deflector down to the height of the dimples and DAd it and now all is well. It can use a little more sanding, but I wanted to get it reinstalled to make sure it was ok before I took it to the nth degree.
So now I just have to do the same thing to te other deflector, sans screw-up of course.
Ahh, my eyes are much better now.
n8in8or
I never met a project I didn’t like
As I had hoped, fully tightening the bolts before welding worked - no dimples! So I ground and sanded the deflectors and then gave everything a once-over. Now it's disassembled and off to the sandblaster tomorrow. 
Nosferatu49534
Well-Known Member
Man that's purty. [emoji2]
n8in8or
I never met a project I didn’t like
Got the parts back from te blaster today. Tomorrow they will be put in a basket at work to be sent out for e-coat. 
Jaryd
Extremely Deplorable
looking good
n8in8or
I never met a project I didn’t like
Thanks.
Got them put in a basket woth some of our furniture after work tonight. Hopefully e-coated by Monday.
