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Intercooler Repair with TIG Welder

5:20
16:33
19.8K views

At 5:20 in

Super Sleeper TRIPLE TURBO Cummins DUALLY Going For 2,000HP On The Dyno (We Had Some Problems...)

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What happens here

During a subsequent dyno run, the truck produces massive amounts of black smoke, indicating unburnt fuel, but a boost leak is identified from a cracked intercooler. The intercooler is an aluminum heat exchanger that cools compressed air before it enters the engine. The team removes the damaged intercooler to perform a repair. A Fronius MagicWave 230i water-cooled TIG welder is used to weld the crack in the aluminum intercooler. The welder adjusts the settings for maximum penetration, given the challenge of welding a pre-stressed and used component, ensuring the weld holds securely under high boost pressure.

Goal: Repair a cracked intercooler to resolve a boost leak and prevent power loss.

Tools and materials

  • Aluminum Welding Rods — Filler material for welding the intercooler
  • Argon Gas — Shielding gas for TIG welding aluminum
  • Cracked Intercooler — The component requiring repair to prevent boost leaks
  • Welding Gloves Vulcan — Protecting hands during welding

What they say

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sketchy it is [Applause] oh my god and uh today's shop forecast is cloudy with a chance to call was that just a test run to see if it would go through the wall no it looked like nitrous light out or something so oh do you got one two three four five six straps and a forklift and we got seven on standby just in case one starts to get wild it'll jump up and save the i can day that we have to pull out the old fronius magic wave i haven't gotten to use that thing a whole lot but you're about to test it out we're going to test it today just like that diesel i found the boost leak that there is uh substantial all the america's escaped diesel uh do you want aluminum or do you need me to do it oh that's that's you bro oh you're just a stainless guy stainless real pretty all right well i guess i'm about to clock in here you do stainless really well for someone who never does aluminum i'm gonna get this thing fired up it's seriously the best welder i've ever used like it is so awesome for aluminum and the stinky part is i haven't really done a whole lot of welding since i got it so you know i'm not really complaining at the opportunity to get back in there and do it it's a fronius magic wave 230i water cooled and it's got like you know i came from a basic welder that used all i had were amps and ac balance i didn't even have a pedal so this thing was just arc was all over the place on aluminum but this one it is like spot on and there's there's more settings on than i even know what they do it's just it just works really well well i fixed it it's not pretty but i couldn't get that gap to close the whole way and there's a distinct difference between making something pretty when it's a new piece of material and you get to fit upright and all that stuff and making sure something that's broken doesn't come back apart again like i was sitting there i had the heat you know cranked i mean it wasn't like crank crank but it was high and i'd sit in there and i would let that puddle get big and you know put the rod in and move forward and then i would not add the rod again until that keyhole flooded it because that's how i knew the pedal was wetted down the whole way through the groove to get this stitched up back the right way because the the old belt was on there had almost no penetration because it was just like a good looking weld i could have made it look nicer but we're just trying to get this thing stay together and make 2 000 horsepower

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