Not sure if this is the right place to post this so if its not i apologize. Was bored this weekend so i said what the hell let me polish the intercooler. I got impatient halfway through, so the result could have been alot better but still pretty good compared to what it was. The better/more you sand and polish the better the results. Maybe this can help some of you, idk. I sanded the intercooler with 220, 320, and 400 grit sandpaper. I wet sanded. If the surface is pitted or scratched deeply you may have to start with a rougher grit sandpaper. Make sure to sand in one direction and then the other with each grit sandpaper. For example, sand horizontally and when its all nice and sanded, then sand vertically. I used the brown rouge to polish it with the 6" wheel on the grinder. Before all this, i poured gasoline, brake cleaner, and acetone through the intercooler to clean that gunk from inside of it. Why use all 3 you say? Well, because i had a little of each lol. Was too lazy to go buy some. Remember to boost leak test after reinstalling and enjoy .


Well, here goes:

I didnt have the best tools for the job, but just used what i had:


harbor freight grinder and drill



i bought this polishing kit from harbor freight ($21.99) and bought the 6" swirl wheel you see on the grinder on the previous picure. Honestly, the only thing i used from the kit was the brown polishing rouge and some of the small wheels to get the bars of the intercooler.

before:





that dirt on my finger is from inside the intercooler










here you can see the difference between the unpolsihed and polished surface

after:

 

I admire all the hardwork involved, but how are you going to keep it like that w/out removing the bumper cover?

After the weather / water gets to it, it will oxidize again

I like youre idea of clear coating as I polished the top of my IC & will do the same. Great job

 

you're right...I should have sealed it with clear poly or clear coated it...but for now this will have to do...one day I'll do it again and take my time so the end result is better and seal it...

 

awesome job

 

thx