Intercooler Pipe Fabrication

An intercooler, also known as a heat exchanger, is vital on any high performance vehcile used to cool air that has been compressed by a turbo or super charger.

One of the crucial steps in fitting an intercooler is planning where the pipe runs will go and what diameter they’ll be. We will use a mixture of stainless steel pipe with silicon bends and joiners to accommodates for size transitions between the turbo outlet, the intercooler intake and the turbo outlet to the throttle body as well as routing restrictions from other components within the engine bay.

Our process ensures that our pipe runs take the most smoothly-flowing paths by keep sharp bends to a minimum.

Correct choice of intercooler is also widely important spme tips can be found below.

Two main types of intercoolers which are water-to-air intercoolers and air-to-air intercoolers. Both of these offer similar benefits but work differently as to how they cool and the correct choice will depend on the application being used in as well as cost.

One main question when talking about intercoolers is how exactly do I get more power from one? Some options are:

1 - Choose the correct intercooler type.

Air-to-air systems. These must receive the most airflow possible, this is most commonly done by mounting it in the front of the vehicle as it is usually the most direct path of air. For those that really want to gain as much efficiency as possible, it is essential to direct the air through only the intercooler. This is made possible by building a ducting system around the intercooler itself so that the air has no choice but to pass through it.

Water-to-air systems. These can be mounted anywhere as long as water can be plumbed to it but require additional equipment for this which increases cost.

2 - Size the intercooler properly. The correct size of intercooler is crucial to ensure overheating does not occur.

3. Adding an external cooling system (air-to-air) to aid in cooling the intercooler.

a. Adding fans to the cooler

b. Spraying the intercooler with water

c. Adding a Co2 freezing system


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