How hard it is to modify the end tanks? And what design?
 

I´m considering modifying this(http://www.thesaabsite.com/200505235...ntercooler.jpg) SAAB 9-3 i/c end tanks, but the aluminium seems too thin...

Did anyone tried to modify the end tanks of their stock intercoolers, with good results? Or it´s too much of a trouble?

I´ve tough of folding a aluminium sheet on a metal tube with the same i/c thickness, cut it, make 2 "half moon" ends and drill a hole right on the center to weld the end tube for the inlet and outlet of i/c... I hope i was clear... :-\

Re: How hard it is to modify the end tanks? And what design?
 

yeah, go for it... as long as you can weld aluminum and you make sure you clean it inside and out before you weld it.

Re: How hard it is to modify the end tanks? And what design?
 

super easy, as long as you can weld aluminum. and if you plan to weld any brackets on the top, make sure you tac the top of the ic to the core, or the top will warp upwards toward the core. i learned that the hard way no difference tho still works either way.

matt