ford powerstroke intercooler
 

i can get an intercooler for 20 CDN. The reason it is so cheap is because it has a slight bend in it starting at about the 2/3 point. If i cut off the bad part can i cut off the end tank from the bad part and weld that end tank onto the 2/3 point where i cut it. The intercooler is huge so i think it would be sufficient. What should i do too ensure there are no leaks?

Re:ford powerstroke intercooler
 

pressureize it up to 40psi for a few mins to see if it leaks.

Jeff

Re:ford powerstroke intercooler
 

All I can say is... good luck fitting 2/3rds of a PSIC into a Civic. STILL too freaking big.

If the top half of it is obviously good shape, and you were planning on redoing the endtanks, I say go for it.

Some of my previous arguments against the PSIC may have been due to restrictive stock endtanks.