And here we have the rear brackets welded to the intercooler core and bolted to the cross-tube. This mounting system has exceeded my expectations for stiffness and may have been overkill. The front bracket was designed to be more flexible than the rear brackets to provide some allowance for thermal expansion and chassis flex, but it may not be enough.
Both intercooler end tanks needed holes cut in them before welding on the Vibrant cast aluminum elbows. The first hole for the inlet of the intercooler was far from perfect because it was cut using a hole saw mounted to a hand drill with the end tank in a bench vise. The second hole went much better since it was cut on the mill.
We sanded down the hose retention bead on the Vibrant elbow and test fit it into the end tank. The intercooler outlet location is locked in so we can start mocking up cold-side tubing.
One last mockup of everything before beginning to weld it all together.
Many hours and way too many tungsten regrinds later we have a finished intercooler. Having never welded end tanks to an intercooler core before, this was definitely a trial by fire. Things could have gone better here and there, but overall it turned out pretty good. Now let's just hope it fits…fingers crossed.