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Cracked Intercooler...now what!!!

 
Old 10-27-2011, 08:18 PM
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Cracked Intercooler...now what!!!



This fall is going to be good!!!
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Old 10-27-2011, 08:23 PM
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04 CL55 (sold), 2012 CLS550 (sold), 2014 S550 (sold), 2015 ES300H (DAILY)
sucks...how did that happen?

I guess the next step would be to replace it?
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Old 10-27-2011, 08:44 PM
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Guess I should have bought that aftermarket warranty afterall!
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Old 10-27-2011, 08:58 PM
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What core are you planning to use?
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Old 10-27-2011, 09:07 PM
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I heard a heater core from a Ford Probe was good...lol

Just in the testing stage so far. Ran a few tests with different configurations yesterday.
I have a good idea of what I want to do, making sure to quantify the results before swapping it out.
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Old 10-27-2011, 09:46 PM
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2005 E55
I have a stock heatexchanger if you need one
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Old 10-27-2011, 10:24 PM
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Old 10-27-2011, 10:25 PM
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give jason at buckhead imports a call. he did a custom i/c for chawkins and it seems to be working great
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Old 10-27-2011, 10:53 PM
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2005 E55 Wagon
How did u crack the IC?
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Old 10-27-2011, 11:16 PM
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Originally Posted by jcjmw View Post
How did u crack the IC?
With a saw of some sort. Can't wait to see what you guys can come up with? This is a good year for the 55k flat form.
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Old 10-28-2011, 03:43 AM
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03 E55 AMG, 06 Harley Road King Custom 06 Ram 2500 Cummins, 97 Firebird Race Car, 88 Cutlass Supreme
Clean it up and have it welded back on for a couple bucks? That looks like an easy repair for someone with a TIG welder.
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Old 10-28-2011, 04:18 AM
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Originally Posted by skratch77 View Post
I have a stock heatexchanger if you need one
Thanks for the offer Angelo. I completed testing on HE's last year. This year, we are taking a look at the weakest link.
Originally Posted by LOCO 05' E55 View Post
LOL...wondering how long it would take for you drop in my parched friend. Going to have a nice cold one for you real soon! Thanks again for the hook up.

Originally Posted by 320 dreamer View Post
give jason at buckhead imports a call. he did a custom i/c for chawkins and it seems to be working great
I read his thread and I understand what Jason was after with his end cap work. We have a different approach, working with TTM/Bruce, and I would be interested in comparing results when all is said and done. You guys are hitting Steele on the 4th right, good luck! I'll be watching for updates.

Originally Posted by BBBSS View Post
Clean it up and have it welded back on for a couple bucks? That looks like an easy repair for someone with a TIG welder.
In the end, it will all be like new again, well externally at least...

Last edited by lowprofile; 10-28-2011 at 04:38 AM.
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Old 10-28-2011, 07:01 AM
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well if bruce is in the equation your in great hands!! might as well tell him to look into fabbing a unit for the v6 he will know who asking! yep 11/4 is drag day cant wait. temps in the 50's and sub da!
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Old 10-28-2011, 09:58 AM
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I was amazed when I split one open-

3 way pass on the ic!!??. also very restrictive in terms of air side. I still have my prototype, but never continued with RD... Had other mods to get to. Let us know how it goes
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Old 10-28-2011, 11:43 AM
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2003 E55 & 2014 GL550
While not common, my buddy Ken at the dealer said he has seen a half dozen maybe over the years. Guys dont even know until the supercharger shuts off and they pop the hood to find the engine cavity filled.

Scary
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Old 10-28-2011, 11:55 AM
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Brabus K8 E55 05
You have 3 choices:

1. Get it fixed or get another stock one around
2. Get another better one (Chawkins) already had something working.
3. Contact PP Performance, google them or get their Facebook, they have intercooler set up for 2700 Euro. I think but i am not sure it is top mount because the guy asked me is your SC E55 with the 2 TBs, then he asked me we will need to get different TB for the new intercooler, I didn't go that way but I wished so since then.
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Old 10-28-2011, 12:14 PM
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Originally Posted by 320 dreamer View Post
well if bruce is in the equation your in great hands!! might as well tell him to look into fabbing a unit for the v6 he will know who asking! yep 11/4 is drag day cant wait. temps in the 50's and sub da!
Good luck!
Originally Posted by Bramage View Post
I was amazed when I split one open-

3 way pass on the ic!!??. also very restrictive in terms of air side. I still have my prototype, but never continued with RD... Had other mods to get to. Let us know how it goes
We should, "should" being the operative word, have this running and tested within two weeks. I'll post our findings.

Originally Posted by Jakpro1 View Post
While not common, my buddy Ken at the dealer said he has seen a half dozen maybe over the years. Guys dont even know until the supercharger shuts off and they pop the hood to find the engine cavity filled.

Scary
When this i/c was removed there were not any prior issues related to it. None the less, we will pressure test it before installation. Thanks for the heads up.
Originally Posted by ahmad0658 View Post
You have 3 choices:

1. Get it fixed or get another stock one around
2. Get another better one (Chawkins) already had something working.
3. Contact PP Performance, google them or get their Facebook, they have intercooler set up for 2700 Euro. I think but i am not sure it is top mount because the guy asked me is your SC E55 with the 2 TBs, then he asked me we will need to get different TB for the new intercooler, I didn't go that way but I wished so since then.
Thank you.
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Old 10-28-2011, 12:28 PM
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Brabus K8 E55 05
Originally Posted by ahmad0658 View Post
You have 3 choices:

1. Get it fixed or get another stock one around
2. Get another better one (Chawkins) already had something working.
3. Contact PP Performance, google them or get their Facebook, they have intercooler set up for 2700 Euro. I think but i am not sure it is top mount because the guy asked me is your SC E55 with the 2 TBs, then he asked me we will need to get different TB for the new intercooler, I didn't go that way but I wished so since then.
I forgot to mention something about the 3rd point. The intercooler set up includes a new Throttle body too, all parts are original AMG according to PP Performance, Intercooler alone is 700 Euro.
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Old 10-28-2011, 07:32 PM
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for those that didn't quite get it, this is the IC under the Supercharger, and the "injury" was self inflicted. i.e. A cut-off blade on a rotary would be my guess

Good luck to you and Bruce, very interested in the final results. Put that tig to some good use!! If it works, Ill have my spare in the mail tomorrow. I guess Ill have to pay up that 12 pack I still owe Bruce!
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Old 10-28-2011, 07:41 PM
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^ I have no idea what you are talking about. Faulty welds I tell you...
Thanks for the good luck wishes.

Here is a shot of the core for those interested.

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Old 10-28-2011, 10:02 PM
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Brabus K8 E55 05
Some people around the forum mix up HE and Intercooler. Some of them call the HE an intercooler, which is mis understanding.

As Bramage said, IC is under the supercharger, you can not see it unless you take out the supercharger.
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Old 10-28-2011, 10:03 PM
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Originally Posted by lowprofile View Post
^ I have no idea what you are talking about. Faulty welds I tell you...
Thanks for the good luck wishes.

Here is a shot of the core for those interested.

A Closer look of the weakest link of this 55 platform

BTW Stoli for me
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Old 10-28-2011, 11:19 PM
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Originally Posted by lowprofile View Post
^ I have no idea what you are talking about. Faulty welds I tell you...
Thanks for the good luck wishes.

Here is a shot of the core for those interested.

Can you please get better closeup pics? From this view it doesn't look half bad. I want to see the air passages ( which I've seen in person but honestly cannot remember..lol ).

Originally Posted by ahmad0658 View Post
Some people around the forum mix up HE and Intercooler. Some of them call the HE an intercooler, which is mis understanding.

As Bramage said, IC is under the supercharger, you can not see it unless you take out the supercharger.
ACTUALLYYYYY..... they are BOTH heat exchangers. The ONLY reason why one is called an intercooler and the other a heat exchanger is to not mix them up. But they are both the EXACT same thing. They both transfer heat from one thing to another ( one is from air to water and the other is from water to air ).
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Old 10-28-2011, 11:48 PM
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Originally Posted by LOCO 05' E55 View Post
A Closer look of the weakest link of this 55 platform

BTW Stoli for me
You got it. Just one catch...I pick where and when.

Originally Posted by GT-ER View Post
Can you please get better closeup pics? From this view it doesn't look half bad. I want to see the air passages ( which I've seen in person but honestly cannot remember..lol ).
The patient is in the process of being of stitched back up. The next time I lay eyes on her she will be ready for pressure testing.
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Old 01-21-2014, 11:07 PM
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2004 E55
Did you ever get this working? Or did you find out there is really no way to make it better. I have a stock core opened up, was thinking to make it single pass instead of 3, but my testing shows there is simply not enough water volume/pressure to use the entire core at once. Seems this is the reason for the original triple pass. When the tanks are opened up for single pass,what you end up with is only 1/3 of the core with the water flowing through. The other 2/3rds is dead, with no flow. You'd have to have an inlet the size of a radiator hose to provide enough water to soak the entire core in one pass. At least that is what I'm finding.
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