Making Parts

On the Datsun Roadster project, I also had to modify the intercooler to make it fit in the car. Here's the skinny.

The intercoooler is an ebay special, but the core is very big for this application. With the cast end tanks and outlets installed it was way too wide to work in the Datsun.

I cut both end tanks off with the bandsaw. This gave me a nice straight cut.

This is the driver's side, I started by welding a flat piece of aluminum plate over the end of the core and then added this aluminum mandrel bend.

I finished by welding this beaded section to the end of the bend. These beads give the hose and band clamp something to hold on to.

Here's the revised passenger side outlet.

I had to weld these short bead section on after the fact because the machine that makes the beads needs a 3 or 4 inch long straight section of pipe to grip on to.

Here's the modified intercooler installed, you can see it's way overkill for the application. But it sure looks cool!