alloy intercooler pipes

[simonallen]

Hi Guys,
I have some alloy intercooler pipes to weld. I am a bit sceptical as to whether I am going to be able to weld them successfully, as tey are the cheap ebay universal kit ones that the guy wants welding instead of using silcone joiners.

These are the pipes I am on about:
http://www.ebay.co.uk/itm/2-5-TURBO...arts_Vehicles_CarParts_SM&hash=item2c567be80e

is the alloy material likely to cause a problem? what sort of filler material would i need for an unknown alloy? I have ony ever welded with the wire that was used by the company I worked for, I have never chosen it myself so wouldn't know where to start.

Cheers,
Simon

 

[julieanncharters]

ya happy butt welding 1.6 mm Ali tube, if so no prob.
would imagine 5356 tig rod on the 6061 grade quoted if its the same kit as the one listed.

 

[Alex-the-tig]

I recently welded some intercooler pipes that were anodised (no colour) the welds became massively porous and wouldn't hold any pressure. If you do end up with this tube, thoroughly prep the joints 3/4" either side in and out with a flap wheel

 

[pc18]

i know a guy that does lots of custom stuff with cars including lots of intercooler/charger cooler setups and he just buys the cheap toyo sports universal intercooler kits off ebay and welds those pipes fine he uses 5556 rods i think.

 

[J_K]

I did a load of this stuff for a custom setup for a mate.
Used 5556 rods.
Had lots of porosity. And the different thickness of pipes wasn't nice.
But we made a pressure testing setup with some stainless bungs, silicon joiners and a schraeder valve.
But 3 bar in and squirted with soapy water to find the pin holes. After about 3 hours, it would hold 2 bar overnight and the loss was probably from the silicon joins.
Wasn't a very pretty job come the end though.

 

[langy]

The aluminium used to make the cheap pipes is poor quality, that's why you get problems, buy good stuff and it will be easier, been there and got the T shirt

 

[NDriver]

The aluminium used to make the cheap pipes is poor quality, that's why you get problems, buy good stuff and it will be easier, been there and got the T shirt

Sorry for the thread Hijack but any idea as to where decent quality pipe/bends can be purchased.

 

[3MPS]

I would also like to find a good supplier for aluminium boost pipes.

 

[lotus_esprit_s1]

I bought some from james lister Motorsport in birmigham a few years ago, they welded perfectly when I cut and welded them.

 

[3MPS]

A mate of mine uses a company but I can't remember the name. Something like PTN motorsport and they sell Vivid Racing aluminium parts. Can't find them on the Internet though.

I'll have a look at James Lister.