Extreme Turbo Systems - How we build real quality and performance!
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Former Sponsor
iTrader: (91)
Joined: Mar 2007
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From: Vancouver, WA
Extreme Turbo Systems - How we build real quality and performance!
Since starting at the custom fabrication facility that is ETS I’ve been blown away by just how much goes into the processes of designing, developing and producing the parts that we offer to our customers. For that reason I wanted to include you guys in seeing the cool behind the scenes stuff!
There are many in the EVO community buying and reselling cheap and already finished product (intercoolers, piping, manifolds, etc.) and often doing so from their apartment, basement or garage. While this is great for a quick profit, it offers no consideration to the EVO owner for quality, performance or value. While we could do the same, we choose to hold our products to a far higher standard.
At ETS we take the highest level of pride in the parts we design, their performance, and the value they provide to the EVO community. Everything we sell is built from concept to finished product in house in Washington State, USA. We have complete control of the entire process and for that reason can ensure that our customers receive the absolute best bang for their buck.
Here are some shots of the process required to build one of our EVO intercoolers and the steps we take to be sure that they perform to the absolute highest standard.
Bare sheetmetal cut into shape to fabricate end tanks
The metal forming process begins
Shortcut to tanks formed and tacked
Finish welding
Finished tanks - inlet/outlet being drilled
Inlet/Outlet being welded in place
Completed end tanks - inlet/outlet beaded
Once completed, the inside of the tank inlet/outlets are ported to ensure the highest possible flow
Completed intercooler pressure tested to 50psi to make sure it will take everything you can throw at it
And that's it, to make a long story way short
I'll have more behind the scenes soon!
Tom
There are many in the EVO community buying and reselling cheap and already finished product (intercoolers, piping, manifolds, etc.) and often doing so from their apartment, basement or garage. While this is great for a quick profit, it offers no consideration to the EVO owner for quality, performance or value. While we could do the same, we choose to hold our products to a far higher standard.
At ETS we take the highest level of pride in the parts we design, their performance, and the value they provide to the EVO community. Everything we sell is built from concept to finished product in house in Washington State, USA. We have complete control of the entire process and for that reason can ensure that our customers receive the absolute best bang for their buck.
Here are some shots of the process required to build one of our EVO intercoolers and the steps we take to be sure that they perform to the absolute highest standard.
Bare sheetmetal cut into shape to fabricate end tanks
The metal forming process begins
Shortcut to tanks formed and tacked
Finish welding
Finished tanks - inlet/outlet being drilled
Inlet/Outlet being welded in place
Completed end tanks - inlet/outlet beaded
Once completed, the inside of the tank inlet/outlets are ported to ensure the highest possible flow
Completed intercooler pressure tested to 50psi to make sure it will take everything you can throw at it
And that's it, to make a long story way short
I'll have more behind the scenes soon!Tom
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Joined: Dec 2006
Posts: 67
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From: So Cal
I love mine. Huge core, fits well with stock bumper crash bar, and the bugs wash out of the fins way better than my stock one lol 
I'll post some pics of it installed along with the 3.5" turbo back as soon as I find my usb cable, I set off my first car alarm a few days ago!
I'll post some pics of it installed along with the 3.5" turbo back as soon as I find my usb cable, I set off my first car alarm a few days ago!
Thread Starter
Former Sponsor
iTrader: (91)
Joined: Mar 2007
Posts: 8,685
Likes: 54
From: Vancouver, WA
To answer the core questions, it is a vacuum brazed 100% bar and plate core designed by us. The core of the bolt-on intercooler that is shown in this thread in the fabrication pictures and on jbfoco's EVO is 25x11.5x3.5". We also offer the two largest race intercoolers available for the EVO. Those versions are 25x11.5x4" ($689) and 25x11.5x5" ($849) but both require modification or removal of the bumper bar and are intended for extreme horsepower applications.
To detail the design of our bar and plate core and why it's superior even to other bar and plate designs- the internal fins are offset and staggered to ensure the highest possible flow and air to fin contact while maintaining maximum efficiency. The external fins are louvered to offer the best possible heat dissipation while maintaining airflow to the radiator, superior even to the thin stock intercooler. Coolant temperatures don't budge on the AEM Serial Gauge or stock gauge even without the driver's side fan in 105 degree heat.
Other kits will include bar and plate core but it is often completely different. With louvered internal fins these kits can be efficient, but the turbulence created limits flow in a pressurized environment like the inside of an intercooler. Therefore similarly sized cores can flow quite a bit less and limit horsepower potential. If you want to delve even deeper as to why our core is superior, don't hesitate to PM me!
Tom
To detail the design of our bar and plate core and why it's superior even to other bar and plate designs- the internal fins are offset and staggered to ensure the highest possible flow and air to fin contact while maintaining maximum efficiency. The external fins are louvered to offer the best possible heat dissipation while maintaining airflow to the radiator, superior even to the thin stock intercooler. Coolant temperatures don't budge on the AEM Serial Gauge or stock gauge even without the driver's side fan in 105 degree heat.
Other kits will include bar and plate core but it is often completely different. With louvered internal fins these kits can be efficient, but the turbulence created limits flow in a pressurized environment like the inside of an intercooler. Therefore similarly sized cores can flow quite a bit less and limit horsepower potential. If you want to delve even deeper as to why our core is superior, don't hesitate to PM me!
Tom
