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My Water to Air intercooler install

Powder coating I believe. Electrostatic charging of the parts and sprayed with powder. Then baked on.
 
Ive been following this for ages and lurking in the background. Its just my type of over complicated project. Love it.
 
ak diesel driver said:
what exactly is e coating?
Click to expand...

Sand said:
Powder coating I believe. Electrostatic charging of the parts and sprayed with powder. Then baked on.
Click to expand...

E-coat is a base coat that we put on all of our products before powdercoat. It's the black coating that you see on replacement body panels. It's also on the frames of new trucks, etc.. The place that does ours in Elkhart, IN does all of the local RV manufacturers' motorhome and trailer frames. They also had a contract to do Hummer frames and components, but I'm not sure if they still do. It's an impressive facility. It's a 14-stage process with multiple dunk tanks with different chemicals and a final cure in an oven. If I recall, the main part of the coating that does the real corrosion prevention is an epoxy, though it also uses a zinc coating as well. The only problem with e-coat is that it isn't UV stable, so it needs to be top-coated. It makes a fantastic basecoat though.
 
Sand said:
Ive been following this for ages and lurking in the background. Its just my type of over complicated project. Love it.
Click to expand...
Thanks Sand.....I think ;) There is an elegance in being able to execute a project simply, but a lot of times that just isn't practical given all of the limitations (the main usually being money...).
 
Looking good man. I know you are glad it's almost done so you can start the install.
 
ak diesel driver said:
It is really looking good but I want to see if it's more efficient now. Function before form I say
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Right on. Unfortunately I haven't had an IAT sensor installed since I did the mechanical conversion, so I won't have a way to see if it's more efficient. I'm hoping to get an IAT installed at some point in the future - when I do I will be able to compare it to what they were like with the DS4 at least, just to see. But year, it would be nice to see the difference it makes, if any, to move it out front rather than being under the truck. One would think it would be a huge improvement, but without data, one never knows.
 
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