I bought a brand new intercooler for $50 bucks. Its dimmensions are 28" tall, 30" wide, 2"thick. Its a really nice unit, I was just wondering if I could cut this thing in half longways with the passages that go across it and have custom end tanks made for it. I know it would theoretically work, but should I bother with all that work or should I just sell this monstrosity for a better sized intercooler. It is a really good brand though, its a behr. Behr supplies Ferrari with some of their oem intercoolers. Any feedback would be great, thanks in advance

 

if you want to spend the time and the money it would probably be worth it. theres a guy that takes powerstroke intercoolers, cuts them down, welds end caps on them, shines them up and sells them on ebay for like 400 bucks a piece.

 

I bought a garrett one off a semi for 100 cdn and cut it into 5 -6" sections they are really wide and require a lot of cutting but look sweet.

All i did was cut thru all the fins and then throught the endtank leaving a lot of it and then cut it all out. Dont cut it close to the fin part tho. Then I ground down a bunch and welded some high quality aluminum for end tanks. Added 2 2.5" inlets and its all good. checked for leaks first of coarse.

I would get it done if I did it again because of the hassle grinding and getting pieces to line up perfect ttoo k me about 8 hours.

Also I sold the other 4 cores on ebay for like 60 US a piece

 

Im planning on doing it myself, I just dont have access to anything that can weld aluminum. If nothing else I will cut all the peices myself and just have a shop do the welds

 

That is the best way. I also used a mig welder somehow to weld the aluminum dont ask me how i still dont know how it worked

 

you can use a spool gun on a mig to weld it.