Restoring WTA IC project

Q&A regarding engines, turbos, and intercoolers and power upgrades

Restoring WTA IC project

Postby CMS-GT4 » Tue Nov 27, 2007 4:35 pm

So, I pulled my st205 wta IC, and stripped the top to repaint it. After stripping it, I found that someone had already tried to repair dents in the past. They used something to fill the dents, though I am not sure what.

Anyone have suggestions on what I could use to fill the dents on the IC and sand smooth?

My plan is to try and make everything look perfect then paint with a gloss black hi temp paint.

I would like to source the OEM metal intercooler sticker. Does anyone have a part number or source for these?

I am using an old technique for helping with heat soak. I have a heat blanket that I am going to glue to the bottom and sides of the IC. So i am not worried about repainting the bottom. The bottom paint is in good shape anyway.
I have an old email that suggests using Dow Corning Hi Temp silicone but I have not been able to source it.

Does anyone have a suggestion for an adhesive with a high temp rating to use on the bottom of the IC?

I will post progess and pics as I do this. I have already stripped most of the paint using a wire brush type bit for a drill. For the side I am using a wire brush. I am avoiding getting any particles inside the core.
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Postby toayoztan » Tue Nov 27, 2007 6:47 pm

You could try sanding down the dents to bare metal and filling it in with Quick Steel (spelling?). It's a long stick of putty you can pick up at automotive stores. After it dries, you can sand it down smooth. I'm not sure though about how receptive it is to paint and what not...i'd imagine there wouldn't be issues painting over it.

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Postby ST185pinjo » Tue Nov 27, 2007 8:57 pm

I have a heat blanket that I am going to glue to the bottom and sides of the IC.


There is special adhesiv meterial for this.

http://www.thermotec.com/product_detail.php?prd_id=13

for sale here for example.

http://www.autobarn.net/thalheba.html

Jou will have to touch the adhesiv stuff as little as needed, because it loses it's power to stick.
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Postby CMS-GT4 » Tue Nov 27, 2007 9:17 pm

Looks like they make a spray as well.
http://www.boostplanet.com/hd_adhesive_spray.htm
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Postby Shaggz00 » Wed Nov 28, 2007 12:32 am

I wouldn't recommend the adhesive backed heat blanket. Lesson learned, there... The adhesive will eventually peel off from the blanket leaving it looking like crap. I've never tried the spray, but it sounds promising. Go for it.
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Postby CMS-GT4 » Thu Nov 29, 2007 2:26 am

I ordered the spray, and this metal filler to take care of the dents.

http://www.alvinproducts.com/Products/Products.asp?ID=1

I think it was the same thing used.

Speed toys is also looking into ordering me the intercooler sticker.
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Postby Fourplay » Thu Nov 29, 2007 10:14 pm

Watching with interest. Will be doing this soon too :)
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Postby CMS-GT4 » Tue Dec 04, 2007 8:38 pm

The metal filler works decent. Needs lots of sanding. I would recomend having some course 300 grit sanding blocks and a smoother sanding block for the final touches.
It does not go on smooth and looks crumbly, but once it sets and you sand off the top layer it looks like aluminum. I finished the first sanding set. I am going to fill the rest and let it set over night to sand tomorrow.

After thats done, I can paint it and then get it back on the car.
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Postby gt4tified » Wed Dec 05, 2007 1:16 pm

If the spray doesn't work, you could always try good old fashioned steel epoxy!
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Postby d1alltrac » Thu Dec 06, 2007 1:41 am

Did you use the hi-temp or regular filler?

Don't forget to post pics of your finished product. :D
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Postby Autobot » Thu Dec 06, 2007 3:40 am

Any pics?
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Postby AW11-Turbo » Thu Dec 06, 2007 9:06 am

here some pics of rebuilding a st205 w/a ic for my AW11 Turbo Project with gen4 3sgte out of an caldina (i'v around 1000 pics from the hole project... maybe posting later if someone is interested)

comparison of st185 cs ic and st205 ic
Image


rewelded st205 ic (caldina manifold is sidefeed)
Image


removed the old paint
Image Image Image


Image


sprayed with heat proof spray
Image


insulated
Image Image


and here the metal sticker with the part number (11286-88480) i ordered for a friends st205 on which me made a gt28rs conversion (also many pics available)
Image
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Postby d1alltrac » Thu Dec 06, 2007 9:57 am

Nice work...thanks for the part numbers.
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Postby CMS-GT4 » Fri Dec 07, 2007 1:54 am

Nice work. Here is my progress so far.


I also came up with a trick for removing the IC faster.
You work the turbo to IC coupling up the pipe of the IC. Once its off the turbo, you can pop the intercooler out. Other wise it is a big pain in the ass to remove.


Here is what I started with.
You can see the scratches, but there are small dents as well.
Image

After removing the IC with the trick mentioned earlier, I taped up all the water and air ports to minimize and dust inside. I don't want to clock up my pump or get gunk in my engine.
Image

Here is the stripped intercooler. While stripping it I found that it had worse dents that I thought and had been filled before. I wanted to smooth all this out and make it look much better.
So I filled it with lab metal. Its like a thick putty. It is course and does not go on smooth so it takes a few rounds to get it just right. I over filled the bulk and let it set over night. It is supposed to take about 2 hours though.
You can see here the rough 1st coat. I used some course sand paper and a sanding sponge to smooth it out.
Image

Here is after the 1st round of sanding. It flush with the metal but you can see some rough spots where I did not fill enough or areas I did not fill at all.
Image

I went back to fill a second time.
Here you can see after the filling is done and it starts to harden. The top layer is crumbly. As you work with it, it turns to this, so you have to work quick.
Image

Here is the finished second sand and the tools I used. Its filling better and is getting smoother. Its a different color but seems to blend well.
Image

I am now on the 3rd fill. I plan on this being the final.
Its pretty smooth and is filled fairly well.
I have already accepted that it might have some slight flaws but not enough to notice or spend more time on. If one wanted something to be as good as factory, it could be done but I am happy with what I have.
I washed and degreased it. Tomorrow I am getting an adapter for the hoses to fit better and then I will retape it and paint it.
Image
Coldiron
92 st185 (205 swap) | 03 350Z Track (sold) | 13 Pilot | 17 Mazda3
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Postby robolt » Mon Dec 10, 2007 2:55 pm

Anyone have a source in the US to order the ST205 intercooler sticker?

P/N 11286-88480

I would also like to redo my IC.

...thanks,
.....robert
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