Finally got the intake hat done.

[F350camper]

Phase one of my intercooler project is complete. FINALLY

It’s a little cruder than I would like, and I’ll have to spend some time cleaning up the casting, but I finally got my intake hat done. The notch allows for clearance of the turbo exhaust housing, and wastegate. That banks turbo is so close to the intake, it really limits intake hat options. Probably the only drawback I’ve been able to find with the banks turbo so far.

Here’s a test fit on an intake manifold that paid the ultimate price. I’ll try to do a test fit on the truck some time this weekend.

 

[budtoh3zo]

Looks good. Good job Rob

 

[Russ]

Rob did you make that intake hat, or is it someone elses?

 

[F350camper]

I made it. Its not perfect, but not to bad for a guy with some sand and a propane tank in his garage.

 

[budtoh3zo]

U got any pics as u built it?

 

[F350camper]

Not really. I have several shots of the wooden mockup going together, but not much of the metal casting process.

 

[Russ]

Wow that's incredable!!! Nice Job!!!! I love to hear more about the process. I'd like something like that so I could get rid of the airbox set up on mine. Intercooler now that would be a plus.

 

[F350camper]

I'd be glad to share Russ. Sounds like a good campfire story.

 

[F350camper]

Here's a couple more pics after I got the casting cleaned up. And a few of a test fit on the truck.

Take note of how the wastegate actuator hovers over the center of the intake hole. I didn't want to change the geometry of the WG, so I added the notch to the casting.

 

[budtoh3zo]

Looks good. might have to make a few more and sell them.

 

[towcat]

Here's a couple more pics after I got the casting cleaned up. And a few of a test fit on the truck.

Take note of how the wastegate actuator hovers over the center of the intake hole. I didn't want to change the geometry of the WG, so I added the notch to the casting.

That casting of yours looks better than what I got from ATS.

 

[Agnem]

Rob, that's incredibly top notch! In my live steam hobby there are a lot of guys who talk of doing their own foundry work. I've seen the kinds of rigs they have to put together, and it's not easy. I'm sure you have a lot of time sunk into that thing. Bring the wooden form with you to Ohio! I'd love to see it, and it would definitely add to your conversation piece. Once again, your a real pioneer, and an inspiration to all.

 

[F350camper]

Thanks for all the positive comments guys. And you’re right Mel, I have quite a chunk of time in that little baby.

I’m pretty happy with it, but I’ll probly pour another one eventually. The sand I used for the core was just a bit too coarse. So instead of a nice slippery path for the air, it’s rather rough. But it’ll do the job for now. Ah, who knows, maybe I’ll just leave it alone. In any case it’s good enough to keep my intercooler project rolling.

budtoh3zo, thanks, ya I spose I could sell a few. But I’d have to get a lot better at it. I certainly wouldn’t sell this one, the pics don’t show it all that much but it has quite a few cosmetic defects.

One additional thought guys. I love my Banks turbo, and in the end I guess it won’t matter, but I have to say the location of the WG actuator is a strike against Banks. After what I just went through, I’d have to lean Hypermax.

 

[Darrin Tosh]

Very Impressed Rob, Looks Great from Grand Rapids! I cant see any inperfections at all. Looking forward to seeing the completed project in July.

Darrin

 

[tuckerd1]

Like the others have said, "I'm impressed."

If the casting is rough inside and it bothers you, get your dremel or air grinder out and do a little "polishing."

Don