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My Water to Air intercooler install

ak diesel driver said:
what about a pipe the right diameter and just use 1/4 of it?
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Possibly, but I would think it would be hard to find a tube in that diameter with a reasonable wall thickness. Plus it looks like it's going to be a decreasing radius piece, so even a tube will need some adjusting. I don't think it's going to be too bad to make a piece that fills the gap, just gotta get to it. Probably Saturday.
 
n8in8or said:
Hmmm, I wouldn't have thought to quench temper them. Why do that? I'm still learning metal forming. I'll probably do as much cold-forming as I can.
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Once you're sure of the bend being what you want, take the heat back up until it's beginning to turn from bluish to the start of a dull red and then quench the part in a large bucket of water. This will temper the metal and it will not only be hard, but will hold the shape of the bend indefinitely. Heck, you could even sharpen the leading edge of the bend and really slice through those corners!
 
Husker6.5 said:
Once you're sure of the bend being what you want, take the heat back up until it's beginning to turn from bluish to the start of a dull red and then quench the part in a large bucket of water. This will temper the metal and it will not only be hard, but will hold the shape of the bend indefinitely. Heck, you could even sharpen the leading edge of the bend and really slice through those corners!
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Gotcha. Ginsu bumper!!
 
I reinstalled the bumper tonight for test fitment. It looks good I think. It's looking more and more like it's supposed to be there. IMG_7842.JPGIMG_7844.JPGIMG_7846.JPGIMG_7848.JPGIMG_7850.JPGIMG_7852.JPGIMG_7854.JPG
 
Then I started figuring out what the missing piece will look like. I made a piece out of cardboard. It's almost half an inch longer on the top than it is on the bottom. As long as I can form a nice radius it shouldn't be bad to fit, but that will be the trick for sure.... Tomorrow is when it will turn into metal. IMG_7855.JPGIMG_7856.JPGIMG_7857.JPGIMG_7858.JPGIMG_7859.JPGIMG_7860.JPGIMG_7861.JPGIMG_7862.JPG
 
sctrailrider said:
A simple job... rubber mallet & thick news paper on a curved object and 5 minutes, start with a larger piece of metal then lap it to the other part and then make your cut.... 10 minutes your done...:wacky:
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I hadn't thought of thick newspaper. Nice tip! Thanks!
 
In the one pic where you can see the front and side together it made me think it would look good if it were a shiny silver or chrome. Would tie it all together with the wheels and chrome edge of the running boards.
 
ak diesel driver said:
In the one pic where you can see the front and side together it made me think it would look good if it were a shiny silver or chrome. Would tie it all together with the wheels and chrome edge of the running boards.
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I see what you're saying. Chrome would be durable too.....but my wallet isn't durable enough for chrome :hilarious:

I got approval at work today to get the deflector and grill pieces powdercoated, so the plan as of now is to paint the bumper itself gloss black at home and then have the other bits done in matte black powdercoat. It should be pretty durable and the contrast against the gloss black will look nice I think.
 
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