Thread: Leaky Intercooler

I wouldn't bother with resins or glue - get it welded up - not a big or expensive job if you find the right person to do it. Gluing it up may work, but do you really want to pull it out again if/when it fails again...

I wouldn't be taking it back to whoever worked on it last if they do work like that...

Well the story continues.
I removed the I/C today (what a ***** of a job) and took it up to the bloke that builds things for people that cant do it themselvese. Or Brian as he is known.
Turns out welding these things is like working on a coke can that has been driven over by a steam roller. Brian did a bloody good job and used resin in place he could not weld but all to no avail. The I/C had burst and was a bit of a colander so my apologies to any Monkey Fisted wrenchers I offended.
Luckily I remembered a Ford Sierra Cosworth I/C I bought a few years back to add to my Disco 300TDi but never did. A bit of rummaging and I have an I/C in my hands. Unbelievably it fits in the space though is slightly smaller and the hoses are the same size and will line up with a bit of jiggling. Just need to block off the 19mm pipe that has no use on a TD6 by turning an aluminium plug, Devcon it in place with a roll pin for security.
This will do till a proper I/C turns up
Now I just have to fit it all back.
Pics will follow

Bacicat I do all my own work on my cars. The one P/O spent an absolute fortune at Stealers and I have so far not been impressed at what they have done. Unfortunately I believe this to be a common occurence.

Adrian

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Burst L322 TD6 Intercooler
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Ford Sierra Cosworth Intercooler compared to rooted stock I/C
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Pipe that gets plugged with aluminium plug I turned on my lathe then Devconed it in place with a roll pin for extra security
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Cradle I made to hold the I/C. I believe the factory I/C also supports the radiators above so I made it do just that.
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Old and new. As can be seen the pipes are in slightly different places but this is not an issue

Adrian

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And finally fitted

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Looking down at bottom hoses. I have trimmed the fan shroud to fit.

And only 2 scrivets and one trim screw left spare

Adrian

Nice job.

I need to ask - what happened to the old one??? Can you see what has made it fall to pieces like that? Has it been in or near the sea, or has it got excessive KM? I just want to make sure mine can avoid the same fate...

The old one burst. Top rear core. It buckled up the lid.
The PO lived within 20km of the sea and he put 230000kms on it. I live 150m from the sea and have put over 5000km on it since January. Not to excessive.
As far as I can tell it has never been in the sea. No rust in any of the front I took off.
Most of New Zealand is close to the sea.
Why the questions about the sea?
From research I have done this is not an uncommon occurrence.

Adrian

My questions about the sea are just to see if corrosion was a factor - I know Aluminium doesn't rust, but uncoated it will oxidise and weaken, and this is accelarated by sea air.

You might be right, but I've never heard of one burst before.

Range Rover Turbo Problem Please Help ?? )

Adrian