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I'm putting the plan together to make my first set of intercooler end tanks and have a few questions.

The core is the big volvo core.

For material selection, I'm looking at making the tanks from 0.125" thick 1100 series Al alloy.

I've chosen that for several reasons:

1. I can easily get it in sheets that are longer than my core (some of the other alloys would require me welding two pieces together... not that it's a big deal though)

2. The 1100 is probably similar to the alloy used to make the core (just a guess, but I seem to remember in my chemical engineering education that 1100 series is commonly used in heat exchangers)

3. The 1/8" thickness is the thickest 1100 I can get.

Once I have formed the pieces, my friend who has a Miller squarewave tig and years of experience welding Al will do the welding for me...

One question is should I consider brazing the core to the end tanks or just weld them?

Anything I'm missing? :? Or any advice from those of you who've done this before?

Thanks,
Alan
 

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All sounds good to me, I'd weld as opposed to brazing.
 
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