TFS: How to Build Custom Intercooler Piping

[@jeromeriaubia9224]

I have sifted through over 100 turbo "build" videos. Most are 95% uneducational. This is the 1st one that shows hands on fabrication throughout the whole video. I learned more in 20 minutes than hours of other videos.

[@robhunter2435]

Rivets or not that intercooler piping build is mechanical art...just beautiful. Its a skill I wish I had. If that were my car I would not complain about the rivets. I think it looks pretty nice with the aluminum piping. Good job!

[@craigdouglas8095]

Straight to the point no nonsense information, great job thanks for sharing 👍

[@benabusthethird9751]

Honestly.. Thank you for noise warnings.. I'd also just like to chime in and say thanks for the little bits of wisdom I'm learning from your videos. Appreciate everything you do. Thanks buddy

[@markrich3271]

The Fabrication Series I would love to see some intercoolers cores welded together for those really large custom jobs.

[@WigglingWaffles]

made my own custom intercooler pipes in a weekend using only this video as reference. very well done guide, it really made the whole job less daunting. I never would have thought to cut an angle in half to dodge other parts and was able to clear my sway bar so much better than if i had not known that trick. boost leaks begone

[@TTTexMMMexBBBand]

hello Justin. This is Javier. i just wanted make a statement that you are AMAZING.

[@CrazyDuner]

I use PET tape for powder coating. It's GREAT stuff and like Justin said, it can withstand pretty high temps and leaves no residue which is very important for powder coating. Thanks for the videos!

[@TheFabricatorSeries]

I love the stuff so much that I sell it on my website haha. Thanks for watching!

[@matthewhart1767]

Thank you for the vid. I was a little stressed out about how to properly get this done, but after watching your vid, I was able to fab some custom pipes for my project and I was surprised at just how simple this was! Took a little bit of trial and error, but the methods shown in the video really helped me along in the process. Thanks a ton!!!

[@amaterasu8829]

Justin is like the Bob Ross of custom instillation videos

[@mikejohle3717]

I love your work my friend , but if you have a customer that ever runs methanol injection, it will find it’s way into those those rivets and corrode them. I know it’s injected at the throttle body, but it’s corrosive as hell and I’ve seen the vapors do this over time, please tack weld those because your quality it is amazing

[@TheCycle2300]

Fantastic video. I've been wanting to add a centrifugal s/c and intercooler to my LS and this really helps show the proper way to get all the intercooler tubing done myself.

[@7sins979]

enjoying the automotive fab work while looking for a tig welder.

[@russverbael2089]

This series is the BEST. Well presented, great photography, Justin is a super capable fab'r and excellent speaker. Thanks.

[@daazndood]

woah this was really cool to watch. Very interesting seeing it all come together!

[@zoottoolie8568]

Noise alerts are life savers, keep up the good work subbed

[@MussaKZN]

Good video bro Aussie boilermaker fabricator here doing coolers, plumbing and off road snorkel for ages. It’s funny to see even though were thousands of miles apart fabrication is fabrication “yer that’s were I’m cutting it that looks right there, tack tack perfect! I don’t tag my stuff but I would go a thicker tag and weld it, Unless your using captive mandrel I would have kittens thinking the internal rivet shaft could end up in the engine!

[@coryhalvorson8874]

man, 4 years later and I'm coming back for a refresh now that I have a tig welder... and people are still getting mad at the rivets xD you could take the BOV out, have that 1 7/8" hole open to atmosphere and still build boost.

[@idriwzrd]

Great video, as always. But I wonder, why rivet the tag rather than a few tack welds?

[@TheFabricatorSeries]

It a very difficult weld to make. The tag usually burns away before the tube gets hot enough to get a dab on it.

[@matthewlefaivre2111]

How thick are the tags? Try starting the arc on the tube and slowly move your way over to the tag. If you are melting the tag corner away you are burning too hot. Just make sure you start to get the tube to puddle, add some filler and move over to the tag. Its quite simple. The tags I use are .125 and I don't even use filler and just tack the corners. The above method works great for it.

[@TheFabricatorSeries]

Matthew Lefaivre I've tried every method I know with this welder (which has limited control) and nothing really works. the tags are .065. If they were thicker, I'd have no problem. Haven't had one bend or distort yet, but it would be extremely simple to replace on if it ever did since I use rivets.

[@rayschrum5855]

Matthew Lefaivre of

[@matthewlefaivre2111]

What?

[@stevebarnes9694]

When you do brackets to reduce movement....where do you try to go to and what material do you use.. GREAT video. Thanks

[@tigquisiawelds3582]

All the time i see your videos i learn something new..thanks Justin!

[@EtherFox]

Thanks as always. Also, at 6:00ish, you mean vertical (which is, notably, perpendicular to the ground); no matter which direction you clock it, a 90 degree bend mounted/cut straight on will be perpendicular to tube you are welding it to 'cuz geometry.

[@EtherFox]

This is to say, you were saying you DON'T want to make everything vertical. Unless you did some pie-cut kinda trickery, the 90 degree piece *will* be perpendicular.

[@TheFabricatorSeries]

Valid point, but I'm pretty sure it was understood.

[@failranch9542]

Holy crap this is a good series!

[@AugustGunsZERO]

I'm glad I stumbled onto your channel. It's pretty useful for my eagle talon build. I've only got 300 in the thing and that's because i had to buy injectors and fluids. everything else i've built by hand on it. so i've already made like idk 8 feet of intake for it out of scrap for free. Thanks man

[@TheFabricatorSeries]

Right on.

[@nelagordon24]

I wish I had a shop jack/lift :(

[@Mitutumuch]

all do brody

[@buckshot927tx]

Don’t let that stop ya brotha.

[@robertragland6084]

I wish someone like him lived in my area...im tired of dealing with these shops who cannot fabricate anything!

[@thehappytexan]

Like the kiss approach. My ocd brain wouldn’t worry about the rivets leaking boost, I wouldn’t do it for the “what if” factor of them failing under severe heat cycling and going through the engine. After being a heavy duty diesel mechanic for 15 years, you see some pretty crazy failure caused by $.50 parts. Lol.

[@nycyabber7103]

This video made me 100% confident in the fact that I need to bring my car to the shop 😂

[@dreamfpv7865]

Arrh man I loved it until the rivets 😵 Come on man 😆

[@ericxiong6582]

2 tack welds on each end would have suffice...lol

[@shawne7225]

you know they put rivets on aluminum boats 😵😆

[@brooks3racing1]

shawn e water is a bit more viscous than air, and boost leaks cause havoc with a tune.

[@bax442]

@@brooks3racing1 Rivots do break off. Imagine the piece of aluminium causing damage to the engine and then the cat.

[@ubbynubb]

@@shawne7225 imagine having engineered holes in your boat

[@BulliKid]

So where does buy the metal for all this?

[@velocityshopsales7478]

You would make one hell of an audio book narrator.

[@johngalletta9379]

I'm getting ready build twin turbo on a 2006 dodge magnum srt8 6.1 hemi. I learn alot here

[@OlisGarage]

Phenomenal video. Thank you!

[@chrispearson2663]

89mirageman here from mirageforums. Been watching all of your videos and I am impressed. I've picked up quite a few tips.

[@TheFabricatorSeries]

Chris Pearson Hey what's up!? There's a few MPF guys floating around here. Always cool to see some familiar names. Thanks for watching!

[@trainedmunkie]

Nicely done

[@Norfolk440]

Man I learned SO MUCH from this video. Thank you!!

[@Lords_Of_Ring]

Cool tutorial. I was going to ask why not weld on the tags, but found the answer in other comments.

[@3dbarn547]

I did exactly what he said not to do. Built my whole kit without having my rad installed and yep I dropped the radiator down and added a remote fill and relocated the sway bar because of it lol.

[@s123fro]

What could you use to knock down any welding debris on the inside of the piping? Say it was more towards the middle and you couldn't reach it to sand it down

[@WillRobinsonDanger]

BEAUTIFUL!!!!!!!!! I would mind finding you to build me one for my Saab 9-3!!!!!

[@aaronwowzree]

Very cool. I'm surprised you don't have a bead roller. There are a few ways to make you own bead forming tool using pliers. I'd love to see your take on it!

[@TheFabricatorSeries]

Aaron Wolff I know there are a few DIY tools and such, but I just don't need one.

[@MrTonysector9]

Hi what kind of alumunium and thickness are you hus using ?

[@LSFoxbody]

Do you have a part number on that DeWalt blade?

[@eduardodaquiljr9637]

Would it be possible to adopt intercooler for non-intercooled turbo engine?Example is the case of Delica Starwagon turbo.

[@HyperspeedMedia]

where did you buy the aluminum pipes? I can't trust the ebay one..

[@Runescape.]

they look like ebay ones

[@dcstang67]

Another very informative video. Great job! I actually figured out to use the pet tape on my own about a year ago when welding up some pipes. I had a roll of that tape for doing powdercoating and i figured it would work really well for the welding. Im glad to see someone else doing the same thing with it. On a side note, you forgot to mention the most important part of cleaning out the pipes before final install. What method do you use for getting all the chips and oils out of the pipes?

[@TheFabricatorSeries]

dcstang67 I order the tubes already cleaned and polished. All I have to do is cut and weld. There's almost never anything remaining inside when finished.

[@deanvandeventer6186]

I have a 2260 turbo on my 1.9 seat with a 63mm hot side charge pipe and cold side 76mm but it take a long time for it to boost what size should I fit to make it boost quicker

[@ronielcrewe1277]

could you do a vid on the saw did you use a speed reducer on it

[@benznut7006]

great video, wondering why you didn't purge the inside?

[@TheFabricatorSeries]

Aluminum is not a reactive metal. It does not require back purging and there is no benefit.

[@2slofouru]

I wish there were someone who took as much care building the piping as you, would be nice to get my subie piping custom to be able to maximize fit and minimize the number of couplings. I don't want another crappy fitting ebay kit that still has to be cut anyway.

[@binstrap7612]

Great videos, thanks Justin!

[@anthonyarnold2499]

Great work and you have helped this newb on welding aluminum. I enjoy learning, as we all do, on new ways to tackle these jobs. Keep the vids coming...

[@8SecSleeper]

Not a fan of stress couplers to make the angles right. Especially on the intercooler where it would be hard to get to on the side of the road.

[@rightsidelanechoice7702]

Have you ever used a stick of brazing rod to bend to the angles you want and then take the protractor to the rod to get your angles?

[@TheFabricatorSeries]

I know the method but I don't use it. To me, it seems like something that takes additional steps for a process I can do without it.

[@kingboy19971]

Where do you get your metal piping from?

[@dougmarthaler3066]

How much flexibility do you typically allow in the piping for engine movement vs the solid mounted cooler? Any “rule of thumb” recommendations? (Couplers, etc?)

[@michaelross6281]

id like to see those welds ground down, and the pipes polished so it looks like one piece.

[@BFE08STI]

As a headset user I thank you for the noise alerts

[@TheFabricatorSeries]

I'm glad it's being noticed. Thanks for the feedback!

[@Runescape.]

how much do you charge for a service like this sir?

[@digitalbilly]

great video well explained. learning lots thanks!!!

[@yvestheunissen]

Is back purging not needed for aluminum intercooler piping?

[@timeslipmotorsports]

What do you do when transitioning your 180⁰ and the cut ends are not completely circle (the outside edge is a little more flat then the inside of the 180)

[@jamiethomas4716]

Time to get out the powertig and attempt to do this!

[@alexzepeda9034]

Can you please post a link of where you bought the pre made bends for the piping? I’d like to purchase a few of those! Thanks!

[@Jayhl217]

Keep the videos coming bro!

[@TheFabricatorSeries]

More on the way up to the tube now!

[@dzionassi]

Could you please tell me what size tungsten was used and what amp setting? Just bough my first tig, trying to make custom intake... Not going well...

[@adrianm5147]

Is there any particular place you recommend for parts and materials when building intakes and exhausts?

[@officer2160]

did you not need to bead the egde on the intercooler side?

[@renerostohar]

Nice video, again a lot learing in it. Top...TFS

[@steveguest8028]

This is a great video 👍

[@anakinskypooper5581]

I appreciate u bro big time

[@SlowEarl1]

Looks Great! Thanks for making video.

[@TheFabricatorSeries]

Thanks for watching!

[@johnhenry6822]

Great video! Inspired to work on mine now. Though it may take years to do what you did in this video lol.

[@georgedicker9789]

Thanks for this video man, amazing stuff. Did you not have to roll the end of the pipes? I made some pipes up my self before and after a couple of weeks of some full boost every now and then it popped off the pipe

[@elmeradams8781]

I've heard of people putting a weld bead on the end of they don't have the tool to roll it.

[@all.for.snowmobile]

Do you make an intake pipe, and fix a shilda with holes, on rivets? Is not it better to weld!

[@Lpz_7R]

What does the MP stand for on your tag?

[@brendaneaglen8164]

I'd like this video twice if I could

[@TheFabricatorSeries]

I guess the comment will count as a second like then haha. Thanks for watching!

[@matthiascross5212]

Good video man

[@jimmyherring4349]

Great job

[@Subi_doo]

Are you using a wood mitre saw to cut that? I know intercooler piping is soft, but that doesn’t look like a cold cut saw

[@MrRcarney2010]

yes its a wood saw cuts aluminium like butter

[@tomthompson7400]

why not use bulk head rivets ,,, they are sealed at the end to start with ,,, very handy

[@jonothatsright3231]

Awesome vid man, how do you find the ebay cooler pipe when welding it up? I noticed you didnt back purge i this was a bit of a must do when dealing with elements such as air especially going into the engine? As in the flakey crust stuff that can chip off on the inside of the pipe or do you run a rag/pad etc thru the inside too? Cheers

[@CarlosMontalvoGhigliotty]

Justin what carbide blade is on the chop saw and diameter?

[@halcontv]

what sort of welder is that?

[@JJREKracing]

What size electrode and filler rod?

[@jameslames1630]

Great video as always. Is there any negative affect of welding the tag on?

[@TheFabricatorSeries]

James Lames There is no negative affect to welding it.

[@jonjetleewayne1939]

What welder settings slash filler rod do you use

[@dresdensvo]

What is your tungsten and welder settings for intercooler tubing? Cut deburr and weld , is there more prep off camera?

[@operatesmoothly]

Gtperformance Dresden +1 for welder settings. mostly ac balance and freq. and power source?

[@TheFabricatorSeries]

There is no additional prep than what is seen. Cut - clean - weld. I usually use 1/16" tungsten on this thin stuff and I taper down in amperage with my pedal starting around 85 amps or so (I can't look at the dial while welding). Balance and freq. are automatic on my machine so I have no control over them.

[@dresdensvo]

Just trying to improve my results on the same tubing.using a miller diversion 165 { only get to control amps} with mixed results.

[@TheFabricatorSeries]

Just practice. Dont be afraid to throw some amperage at it and run the pedal to your advantage. When welding, you are basically looking to time your dabs to a split second between the moment where the aluminum gets shiny and the moment that is starts to fall out. The higher the amperage - the faster it happens, but also the less control over the puddle you end up with. You can start high on the amperage while the metal is cold and slowly back the amperage off as you progress. It just takes some practice.

[@weldingjunkie]

Gtperformance Dresden step on pedal until it puddles and then more or less than and go from there. That’s a tough machine for aluminum with no adjustments.

[@jason-things_to_do]

SOS pad shines up aluminium well.

[@TrojanHorse1959]

Great video, very informative!

[@fastsofaracing]

Once again nice and informative video. keep it up.

[@TheFabricatorSeries]

Thanks!

[@terryleyendecker8934]

Thanks that was cool I do pip work to but to see someone else's tricks of the triad helps wasn't to long or over explained nice job o what kind of tape is that didn't realy explain much about it love to see more helpful tips AWESOME VID

[@olee_stunts]

great video!

[@junior08105]

How much a job like that cost

[@muchoos]

Thanks about noise alert : )

[@720engineering9]

Fantastic.

[@greg925911]

could one use V Claps to connect the pieces

[@michaelangel7448]

hey man nice work . when you're doing a custom job, do the placement of the box matter if it's on the cold side of the intercooler pipe or the hot side

[@TheFabricatorSeries]

Michael Angel There will always be an argument regarding hot side vs cold side haha. It's most commonly found on the cold side, but it doesn't matter where you put it at the end of the day.

[@michaelangel7448]

Thanks man

[@dustinwestphal4333]

What blade do you use in your saw to cut the aluminum intercooler pipe?

[@TheFabricatorSeries]

Just a carbide tipped saw blade

[@85nscarola]

I’m interested in doing this myself but only have a dc tig welder. Do you have a go to spot for stainless piping? Most of the kits I found are for exhaust and have exhaust coupling ends. The other option is complete straight pipe and pie cutting but I would much rather have some bends premade.

[@elmeradams8781]

What do you mean spot?

[@85nscarola]

@@elmeradams8781 meant like a local metal supplier or is there a really good place online to buy all piping for reasonable cost? I ended up pie cutting everything. Was a nightmare.

[@elmeradams8781]

@@85nscarola sorry I had welding on the mind and spot didn't make sense. If you find a good supplier let us know.