Intercooler - Scratchbuild How To...

Some time ago Dan (daggerlee) asked me how to go about making one of these. Unfortunately i never got around to doing it til now - sorry Dan! Its something that i want to include in my venture as resin parts in a variety of different sizes and styles. But for the members of AF, here's how to make one. This one was put together in about an hour, no accurate measurements were taken or indepth research - just a quickie!

Stage one - The face of the intercooler is made from a styrene sheet available from Evergreen which has grooves in it, normally used in rail modeling. This is not thick enough on its own so two 30thou and one 20thou plain styrene sheets were sandwiched together

http://files.automotiveforums.com/uploads/322108intercooler1.jpg
http://files.automotiveforums.com/uploads/202086intercooler2.jpg

Stage two - The end pieces are made from 4 triangular shapes cut from 10thou sheet with styrene tubing inbetween.

http://files.automotiveforums.com/uploads/782445intercooler3.jpg
http://files.automotiveforums.com/uploads/400642intercooler4.jpg
http://files.automotiveforums.com/uploads/441404intercooler5.jpg

Stage three - Putty added to fill ends.
http://files.automotiveforums.com/uploads/734316intercooler6.jpg

Tomorrow i will sand it and add the weld seems - stay tuned!

Wow this is great! Thanks a lot yo!

U guys know where I can find these materials on the internet? Nice job fly!

Originally posted by Honoturtle
U guys know where I can find these materials on the internet? Nice job fly!
http://www.dhcinc.com/evergreen.htm

Some time ago Dan (daggerlee) asked me how to go about making one of these. Unfortunately i never got around to doing it til now - sorry Dan!

Haha! Thanks a lot man! You rule!! :D I was afraid I was gonna have to ask you again when I start my R32 ;)

:jump:Thanks alot fly, :wave: this sure does help out alot, :wave: by the way can i you please make a thread on how to make a turbo and a blow off valve:jump: that would be awsome with the intercooler:jump:

The next stage is a bit fiddly so attempt it if your feeling adventurous. Its not really necessary anyway unless your a sucker for small detail - like me :D

The weld seems are made from two part epoxy putty, the 'toothpaste' kind is impractical.
http://files.automotiveforums.com/uploads/961638day2.jpg

Small amounts are rolled out.
http://files.automotiveforums.com/uploads/886284day2-1.jpg

After placing in position an old large bristle brush is used to create the textur of the weld. Its simply rolled over the slither of putty.
http://files.automotiveforums.com/uploads/168534day2-2.jpg

Done! - If you wanted to, you could add more around th pipe and on top but you won't see them so there is little point.
http://files.automotiveforums.com/uploads/243561day2-3.jpg
http://files.automotiveforums.com/uploads/447975day2-4.jpg

Looks pretty cool behind the s2k front, just needs a little paint.
http://files.automotiveforums.com/uploads/866792day2-5.jpg

I'll post more pics when complete and will also extend the piping.

Sorry if I'm alittle slow. I still don't quite understand how you make the welds. Do you crumble the putty around or have it zig zag ?

Ok, nevermind, is it lay the thin strips of putty over the weld area, then run it over with a brush for texture before it dries?

Originally posted by turbos86
Sorry if I'm alittle slow. I still don't quite understand how you make the welds. Do you crumble the putty around or have it zig zag ?

Ok, nevermind, is it lay the thin strips of putty over the weld area, then run it over with a brush for texture before it dries?

I should have explained better but yes, you've got it.

lol lol lol @ the smiley balls! :D :D :D poor fokkers gonna die :devil: mouahahaha!

oh. sorry, i didnt mean to get carried away like that! :licker:

Great how to.(this page has been added to my favourite bookmarks):D

:confused: hey fly, :( what abou that turbo and blow off valve?:confused:

Originally posted by fullbloodchop01
:confused: hey fly, :( what abou that turbo and blow off valve?:confused:

Yeah i've been giving it some thought, i'll try to get something done (there was one on here not long ago, just not as a step-by-step). Also hope to do a suspension build and lowering and exhaust "how to's" in the future.

Originally posted by flyonthewall
Yeah i've been giving it some thought, i'll try to get something done (there was one on here not long ago, just not as a step-by-step). Also hope to do a suspension build and lowering and exhaust "how to's" in the future. Would you be interested in putting them in an article archive, as an offshoot of the Gallery? :D

thanks for the info! So you're using the "V-Groove Siding" sheet? Thanks!!!

Fantastic job Chris, with your talents maybe you should think about going into business!!!!:rolleyes: :rolleyes: :rolleyes:

Seriously though, damn fine and very informative 'how-to...' thread!
But where do you get the styrene stuff from in the U.K?
The link Jay posted aren't taking any more International Customers!!!!


INTERNATIONAL??? PAH WHO DO THAY THINK THEY ARE?
I'M BLOODY ENGLISH NOT INTER-BLOODY-NATIONAL!!!!!!!





P.S Before anyone starts telling me that as nhc are in the U.S so to them I am an international customer e.t.c e.t.c... Please note the above
rantings are a joke!!!!

Originally posted by fatboyslim
P.S Before anyone starts telling me that as nhc are in the U.S so to them I am an international customer e.t.c e.t.c... Please note the above
rantings are a joke!!!! Hence your signature? :lol2:

EXACTLY JAY!!!!

:D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D

Originally posted by jay@af
Would you be interested in putting them in an article archive, as an offshoot of the Gallery? :D

Do u need to ask? What will u do, just have a link to this thread or do u want me to re-work it when its complete with more text?

thanks for the info! So you're using the "V-Groove Siding" sheet? Thanks!!!

I was originally going to use the v-groove but its not really suitable, the "Metal Siding" is better. This is what has been used so far, BTW the tubing is 2.5mm...Oh, and i forgot to include the 10thou sheet, but u get the idea!

http://files.automotiveforums.com/uploads/798738materials.jpg

But where do you get the styrene stuff from in the U.K?

If you take a look at the above pic you should see reference to a model shop near you we mentioned recently.;)

:alien2: hey thanks alot fly:licker: ill be looking foward to ur next how to's:frog:

Oh yes, I guess I'll have to pop over to Nottingham one day with a big wedge of cash to spend!!!

Thanks Chris!:D

Thanks for the info, maybe ill put it on my Subaru Impreza.

The purpose of this next stage is to help hide away the empty space behind the front intake of a curbside kit. So carrying this out depends on what model your adding your intercooler to and the size of the visable area.

To make the pipes i'm using aluminium tubing which you should be able to get from good model stores. The smaller size is 1.7mm and the larger size is 2.4 which makes it about right for the 2.5 inch size tubing on the full scale items. This tubing is quite soft and easily cut through with a No11 blade.

The next few pics are self explanatory but if you've sniffed too much glue and/or forgot to wear your respirator today, then i will point out that two lengths of tube are cut as desired with the smaller diameter cut slightly longer. This is so that it will form a plug to slot into the intercooler. They are then simply cut in two after inserting one into the other.
http://files.automotiveforums.com/uploads/6709581.jpg
http://files.automotiveforums.com/uploads/7599602.jpg
http://files.automotiveforums.com/uploads/7623793.jpg
http://files.automotiveforums.com/uploads/8875054.jpg

The reason for using metal is obviously for realism, the aluminium tubing can be buffed to a nice shine, so thats what i'm gonna do! I first gave the tube a light sanding with 1500 wet and dry then polished with Autoglym Paint Renovator but any polish will do.
http://files.automotiveforums.com/uploads/3064725.jpg
Polished tube below -
http://files.automotiveforums.com/uploads/4859046.jpg
http://files.automotiveforums.com/uploads/4967607.jpg

This will eventually be the intercooler's new home. With the help of some mesh infront it will disguise the fact that no engine exists now that the opening is alot bigger.
http://files.automotiveforums.com/uploads/1004068.jpg

For the next stage i'll show how to add yet more detail to give it that extra realistic look, here's a sneak.
http://files.automotiveforums.com/uploads/8565209.jpg
http://files.automotiveforums.com/uploads/94084710.jpg

:dogpile: god man , you are the "MAN":wave: its a damn good thing that you got that camera of yours, :wave: but by the way is there any set time to when we can expect the other how to-s "blow off/intercooler"
Rui:smoker2:

Keep it coming Chris, I can't wait!:)

Oh man oh man

I ran out today well drove to my local hobby and picked up the stuff you listed. They didn't have any metal siding just V-Groove so I picked that up. They also didn't have no styrene tubing so I picked up some metal tubing and whaaaa.:eek: ...you just posted that you are using metal tubing!:D !!

Umm Fly are you using Jedi Mind tricks if you are it's all good!
Keep the tips comin.:licker:

Awesome! :D

Cool! :):)

I used AlcadII Chrome to paint the intercooler, I can't recommend this stuff enough, its just brilliant!
http://files.automotiveforums.com/uploads/4706921.jpghttp://files.automotiveforums.com/uploads/1266162.jpg

I based this loosely on the Blitz intercooler - I say loosely coz i didnt convert the measurements from the real thing, only sizing it as desired but copying the basic design - so its only fitting to have the blitz logo on it.

I took the logo from thier website, resized it a few times in a photo software package and printed onto some coated paper, then chose the best size.
http://files.automotiveforums.com/uploads/7732763.jpg

I laid masking tape over the image before cutting out the letters. This was just to add a little rigidity to the paper. I opted not to stick masking tape directly onto the part for fear of lifting off some of the Alcad and also because it might lose some of its form. The mask was made to be the same height as the part and markings were made in order to position it in the centre. Dont forget the closed parts of the B's!
http://files.automotiveforums.com/uploads/1759944.jpghttp://files.automotiveforums.com/uploads/7883595.jpg

I lightly airbrushed it with flat black paint, it was only give a few passes to give it a subtle look like on the real thing. It may also be worth trying Tamiya Smoke or a Dark grey for this too.
http://files.automotiveforums.com/uploads/8935196.jpg

With the pipes super-glued in place i cut thin strips of tamiya masking tape to form the rubber band connectors (I'm not familiar with the correct terminology so forgive me if thats not what thery are called) which was wrapped around a couple of times. I applied thin CA to the ends to prevent them from lifting.
http://files.automotiveforums.com/uploads/7625597.jpg http://files.automotiveforums.com/uploads/4727888.jpg

I painted the bands with a flat mid blue. At this stage i applied a heavily thinned wash of satin black into the groves and over the weld seems to bring out the detail.
http://files.automotiveforums.com/uploads/9501229.jpg

To recreate the metal bands i used thin strips of Matt Aluminium Bare Metal Foil.
http://files.automotiveforums.com/uploads/47438210.jpg

To make the fasteners i used 15amp fuse wire, glued in place with a little more thin CA.
http://files.automotiveforums.com/uploads/45114511.jpg
http://files.automotiveforums.com/uploads/84888913.jpghttp://files.automotiveforums.com/uploads/43128112.jpg

The finished product.
http://files.automotiveforums.com/uploads/42579414.jpg
http://files.automotiveforums.com/uploads/86055115.jpg

Hope you have enjoyed this and i look forward to seeing your versions added to your models.;)

You can be sure you'll see one on my Supra and R32 models!! Thanks a bunch!! :flash:

Chris, I don't have an airbrush. What would you recommend I use to achieve the same silver/chrome finish?

Originally posted by turbos86
Chris, I don't have an airbrush. What would you recommend I use to achieve the same silver/chrome finish?

I doubt u will be able to find anything as good as Alcad from a can, although Laurent acheived a similar result on the roll cage to his custom Ford Focus recently. You could ofcourse try any aluminium/silver sprays or alternatively try something else instead - dry brushing silver over a black base coat would be interesting, something i might try on a future one. There's also a few brush on metalic paints available, I have Humbrol Metalcote for example which is OK, and these can be buffed with a soft cloth.

Holy Crap dude!! That is just to cool and detailed!!!! That's going on my civic!:):)

Thanx for all the info fly.

Check out what hirofkd did on his Toyota MR2:

http://www.asahi-net.or.jp/~xr2h-fkd/scalemodels/project/toyota/mr2sw20/sw20p6.htm

Sounds very interesting..

I've been reading this thread each day with much intrest, and i have to say it has been a fantastic thread. Well done on a great write up

Thanks for the comments people, always a pleasure to help anyone improve their models.;)

Thanks! The intercooler I'm making has a BLITZ decal on it. This thread has been very helpful :) I had started on one but was unsure exactly how to finish it to look convincing. Again, thanks! :D

You guys know where hirofkd got those emblems?

I am new and I have a question about that puddy you used for the welds fly. Where do I get that? what is the brand? does it just air-dry?

Originally posted by Bowtie Bubba
I am new and I have a question about that puddy you used for the welds fly. Where do I get that? what is the brand? does it just air-dry?

Welcome dude - another BMC member!;)

I used Miliput for the welds which is a two part epoxy putty (any will do). Should be able to find it or something similar in good model shops and craft stores.

Honoturtle,
Last time I looked hlj.com was sold out of all Toyota and Honda emblems. I'm not even sure if they are in production anymore.

Originally posted by jaykit21
Last time I looked hlj.com was sold out of all Toyota and Honda emblems. I'm not even sure if they are in production anymore. Maybe we could convince Chris to add them to his SAS lineup... ;)

:smoka: yea and maybe chris can add some N.O.S. decals to sas also:sun: , what do you think Chris:smoker2:

Originally posted by jay@af
Maybe we could convince Chris to add them to his SAS lineup... ;)

It was mentioned before, it is something i want to do. Thought about a general set with all the popular manufacturers logo's or do u think a set for each manufacturer would be better along with the badges for the relevant tuning companies (mugen, TRD, nismo etc) and car badges (silvia, GTR etc etc)
http://files.automotiveforums.com/uploads/835271nismo.jpg

yea and maybe chris can add some N.O.S. decals to sas also , what do you think Chris

Already on the case with custom graphics decals that will come complete with a 'buttload':D of sponser logo's - Nos inluded.
Expect previews of designs in the next few weeks.

AH, accidently bought some V-grooving sheets today. Gonna have to return them and look for some metal siding instead :o

Originally posted by flyonthewall
... or do u think a set for each manufacturer would be better along with the badges for the relevant tuning companies (mugen, TRD, nismo etc) and car badges (silvia, GTR etc etc)I vote for this, especially for the manufacturer-specific tuners, then the rest of the general tuners can go in the other set. :)

(Gotta keep the TRD logos of the Nissans, you know! :o)

Originally posted by jay@af

(Gotta keep the TRD logos of the Nissans, you know! :o)

Or Honda's, In the latest issue of Max Power there is a Jordan Civic - which looks very nice - but has a TRD sticker stuck to the front.:rolleyes:

I can't wait till sas start trading!!
Finally somewhere selling quality items and not trying to rip people off!
An added plus of course is he's based in the good 'ole UK!!
So for those of us without c.c's paying will be easy!!

Yah, fly can I use an Internation Money Order? Or u don't want to handle these?

Just let me know where to send the money!!! :) :D :cool:

Originally posted by Honoturtle
Yah, fly can I use an Internation Money Order? Or u don't want to handle these?

Not thought about those yet, never used them but i'm sure they wont be a problem. We can defineately sort something out anyway, seeing as your an AF member!

Seeing as Chris has given us this wonderful tutorial on something a lot of us have a need for, I've been experimenting and came up with some additions to add. I was studying the curves of intercooler piping and found that they could be made from curved sprue pieces as shown below
http://files.automotiveforums.com/uploads/905623tankpipes.jpg
These pipes are for those instances where you want to give the suggestion that the piping is connected to an engine in those kits where you have room to do so; not all models will allow, nor will they need this added detail but I offer the tip anyway. :)
http://files.automotiveforums.com/uploads/890625intclr1.jpg
I also added panel lines to the intercooler shown below...
http://files.automotiveforums.com/uploads/502887intclr.jpg
I only mean to augument what Chris has given us and wish to thank him once again for sharing his knowledge with us.:cool:

Excellent idea! Great lookining intercooler you've built there too!

Awesome intercooler work. So real. And i cant wait for the decal sheets. Just what ive been looking for.
Also, where can i pick up one of those F&F supras like in your current projects?
cheers

Originally posted by ozstrider
Awesome intercooler work. So real. And i cant wait for the decal sheets. Just what ive been looking for.
Also, where can i pick up one of those F&F supras like in your current projects?
cheers

Err...when i get around to finishing it!

Hurry up man, I´m still waiting for it! :D

Nice intercooler! Whut did u make the intercooler out of? Styrene sheets? or whut? Urs look pretty kool, i really like it, will u be selling any? I have already ordered one from FlyontheWall like last week, so he is going to be done with my intercooler around next Monday or soo...

I can't believe I have never thought of using that styrene for intercoolers, I have seen the stuff at my model shop but never thought "Intercooler", man this rocks, thanks FOTW:eek:

lol man a turbo on a s2000?!!! the compression ratios are way to high! you would blow the fuck out of it. if your going to go for forced indution a super charger will work in real life. :eek7: