Recently we posted about why we leak test each intercooler. The post was locked due to a couple vendors/customers bickering back and fourth.

We at ETS feel it's our duty to our customers to pressure check each intercooler to 35psi-40psi before it leaves our facility. You may ask why would you need to leak check an intercooler?

If you purchase a Garrett intercooler you get a little note in the box that looks like this. From our experience the Majority of the Garrett cores leak from the factory and require resealing.



When we build our ETS intercoolers we have them pre pressure checked, then after welding we pressure check again to ensure that we have no leakage.

If you need to pressure check your intercooler. Here is a link from the DSM days that shows how to build a low budget leak tester.

http://www.vfaq.com/mods/ICtester.html

This is a good test to do after installing intercoolers pipes, intercoolers, blow off valves, etc.

Any questions, let me know!

Thanks!

Michael

 

Nice info. I didnt realise Garrett had some issues.

 

Most people don't. The customer has to rely on the manufacture of the product to pressure check each intercooler and fix it properly.

It's all about the quality control.

Michael

 

Some of which don't unfortunately.

 

I wonder if silver solder could be used for pinhole leaks. The idea of using superglue (mentioned in another thread) doesn't sit right with me.

 

No it can't. Some of the leaks are deep within the tube to header area, toward the middle of the core. No way to get weld to them. We have a method of ensuring a 100% leak free heat exchanger for our industrial bar and plate oil coolers.

All bar and plate mfgrs have leakers here and there.

 

Correct, Garrett admits to it but all bar and plate designs, regardless of who builds them, have leaks.

If you have a leak, clean the core, lay it flat on a bench/floor and use super glue on it.

 

Thats why I got the ETS no time for f...ing around with leaks

 

its always good to see what goes on behind the scenes of a product...

 

I will take a video of the next Garrett core that comes through here. We don't sell near as many Garrett cores as we do ETS.

thanks!

Michael

 

Michael,
We have built a leak test jig for cores using a thin rubber gasket, two plates with long bolts to clamp the core. However sometimes when the header bars are a little uneven the gasket won't seal properly. There are some cores that we throw in the recycling bin because it's cheaper to scrap the core than it is to put all the labor into building a cooler, only to have to cut the tanks off because of a leak.

 

very good info, I like the tool link for checking PSI leak. pretty kool stuff!

Thanks!

 

We have a similar process for checking the bare cores. We also do the pressure check after the intercooler is built to ensure a leak free product.

Thanks for sharing!

Michael

 

Great info.

I just pressure tested a stock IC, that got a dent in it and thought it may have had a leak. Tested it up to 30psi, no leaks.

 

I have the AMS intercooler. I did a boost leak test with the motor at TDC. It took 59 seconds to go from 20 psi to 10 psi. There was a small leak from the bov and a very small leak from the throttle body. I have the works shaft seals.