I've welded a lot of intercoolers. Its amazing how much oil collects on the inside. I usually try to acetone the inside of the tank. (Expensive) but it usually helps with welding it up.
Please please tell them you found it and to have a mechanic check it. The turbo passes a tiny amount of oil. But if its puddled up bad in the intercooler/charge air cooler there is a problem with the turbo or pressure in the engine. This is what causes an engine runaway on diesels. Ill send you my welding customers if you send me the ones full of oil 🤣🤣
@@markcnc for aluminum ?!? A waste of time and money …. It forms an oxide layer almost immediately anyways, as soon as the back purchase off of it, regardless of temperature. Now for Stainless that’s a different story.
Ha that's funny you mentioned boost, I said the same thing. Could I also suggest plating the end cap joins as it may also be flexing the welds from the thousands of times it's hit boost. Kind of the unholy trinity of fab work, undersized material + "Sema" welds + BIG boost = boost leaks for days.....!
Wonder if the cracking was caused by the wrong filler rod being used on the original welds? If they used ER5356 filler, it is subject to cracking if the welds are exposed to sustained temps of over 150F. Not sure how hot this part gets, just thinking out loud.
I see this alot on semi trucks as a mechanic. 9 times out of ten its usually the radiator gets replaced and the radiator intercooler/charge air cooler and condenser dont get mounted perfectly back together and then get torqued down. I seen all 3 crack from just mounting wrong. I think it torques the whole thing a little and it just cracks.
I’ll agree with with others, number 5 cup would probably help. I found with a number 8 on aluminum, the arc tends to wander a bit more with inconsistent cleaning.
Those are always very dirty to weld. I always try to clean the inside if possible and sometimes add a backpurge. Try a smaller cup on the torch next time and turn the gas up until you get some turbulence in the weld, then back off from there. It's always a trial and error to weld this stuff because you never know exactly what material you are dealing with.
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I've welded a lot of intercoolers. Its amazing how much oil collects on the inside. I usually try to acetone the inside of the tank. (Expensive) but it usually helps with welding it up.
Please please tell them you found it and to have a mechanic check it. The turbo passes a tiny amount of oil. But if its puddled up bad in the intercooler/charge air cooler there is a problem with the turbo or pressure in the engine. This is what causes an engine runaway on diesels. Ill send you my welding customers if you send me the ones full of oil 🤣🤣
#5 cup might have helped direct your gas at the weld. Helps with dirty aluminum
I like to heat dirty aluminum to maybe 400 degrees for 20 minutes, or so. It helps getting some of the junk out.
Could you have used a propane torch to heat up the work to burn off the oil inside the cooler?
Great explanation, great video,!! 😊
Iv done a few of these, #5 cup lots of cleaning and preheat helps a bunch.
How much boost was he running
Great work as usual!
could filling the cooler with argon (backpurge?) have helped?
Nice job!
Thoughts on not using backpurge?
@@markcnc for aluminum ?!? A waste of time and money …. It forms an oxide layer almost immediately anyways, as soon as the back purchase off of it, regardless of temperature. Now for Stainless that’s a different story.
Excellent video.
Ha that's funny you mentioned boost, I said the same thing. Could I also suggest plating the end cap joins as it may also be flexing the welds from the thousands of times it's hit boost.
Kind of the unholy trinity of fab work, undersized material + "Sema" welds + BIG boost = boost leaks for days.....!
Oh the joys of repairing aluminum.
Wonder if the cracking was caused by the wrong filler rod being used on the original welds? If they used ER5356 filler, it is subject to cracking if the welds are exposed to sustained temps of over 150F. Not sure how hot this part gets, just thinking out loud.
I see this alot on semi trucks as a mechanic. 9 times out of ten its usually the radiator gets replaced and the radiator intercooler/charge air cooler and condenser dont get mounted perfectly back together and then get torqued down. I seen all 3 crack from just mounting wrong. I think it torques the whole thing a little and it just cracks.
I’ll agree with with others, number 5 cup would probably help. I found with a number 8 on aluminum, the arc tends to wander a bit more with inconsistent cleaning.
love it
We like it! :D
Those are always very dirty to weld. I always try to clean the inside if possible and sometimes add a backpurge. Try a smaller cup on the torch next time and turn the gas up until you get some turbulence in the weld, then back off from there. It's always a trial and error to weld this stuff because you never know exactly what material you are dealing with.
Tay there’s a special episode on Steve Morris’s channel where he went to a famous welder’s shop. You should watch it.
Spike must not of done his daily affirmation routine. 😂
You know what you are doing, I see other welders that don't drill holes
Backpurge missing
Random question to feed the YT algo for you: No soapy water pressure testing for QA? Jus' askin'!
Make them steam clean it inside, first, next time!
Back purge might have been helpful.