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Old 11-05-2010, 10:52 AM   #1
nxwrxfx
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Question Metal Work: Expert Opinions Needed

Hey all,

So here's the story:
I recently picked up an APS DR525 kit that was either sent as is or was damaged in transit.
Still working out the details of how the damage occurred with the seller, but long story short I am in need of some expert metal working advice.

On the DR525 intercooler core, the two metal mounting tabs on top are slightly bent downwards were they come off the back of the core. These are the metal mounting tabs that secure the intercooler core to the APS bumper beam.

My question is, what can I do to bent these back to being straight?
I don't want to screw this up with an amateur fix...
I was thinking blowtorch + hammer + jig/brace to hammer on, but wanted other ideas.

Here's a pic of the intercooler as it is stock, and you can see the fronts of the metal tabs i'm talking about along the top of the core:
http://www.tunersports.com/images/pr...0-core_dim.jpg

Also, the APS bumper beam that was sent seems to have a lot of rust particles falling out from the inside... That's going to be another thing to discuss, but at the moment it seems structurally solid... Will post up pics tonight.

I will post up pics of the actual intercooler core and bent tabs tonight too, and thanks for any advice given!
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Old 11-05-2010, 12:40 PM   #2
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its aluminum. are they broken or just bent down a bit? i've had good results using a large crescent wrench. just get it snug on the tab and bend it up at the bend point. i dont htink i'd want to use any heat and change the temper of the alum.
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Old 11-05-2010, 12:55 PM   #3
nxwrxfx
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just bent a bit, not a ton either. one side is maybe 10* bent down, the other one isnt more than 20* or so. both metal tabs are literally bent where they dip off over the backside of the FMIC core too, so i'm really hoping i can flip it upside down, brace it, and bend them back!

Thanks tom! I will try to crescent wrench approach tonight when i get home.
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Old 11-05-2010, 01:20 PM   #4
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the one we installed for a customer had the same problem. it'll bend easier than you think.
they do a **** job packaging them for sure.

t
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Old 11-05-2010, 01:32 PM   #5
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woot! you just made my weekend man!
excited to get home and get wrenchin' on this now
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Old 11-05-2010, 01:42 PM   #6
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just go slow.
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Old 11-05-2010, 01:59 PM   #7
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got it, little at a time.
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Old 11-05-2010, 04:44 PM   #8
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Actually I'd heat up the tabs to 700-900 deg F and then bend them when cool. That should put them back into a dead soft/T-0 condition. Real easy to straighten. Then I'd heat them back up and quench them in a tub of hot water. This will restore the solution part of the heat treat and time will restore the age.

Just a dumb Al foundry engineer.
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Old 11-05-2010, 04:58 PM   #9
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^^ okay for this... if i cant get it by hand with a wrench....
Would a small propane bottle blowtorch produce 700-900* F?

You are talking to an absolute greenhorn when it comes to metal work/welding/etc.
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Old 11-05-2010, 07:58 PM   #10
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Quote:
Originally Posted by Web Foot STi View Post
Actually I'd heat up the tabs to 700-900 deg F and then bend them when cool. That should put them back into a dead soft/T-0 condition. Real easy to straighten. Then I'd heat them back up and quench them in a tub of hot water. This will restore the solution part of the heat treat and time will restore the age.

Just a dumb Al foundry engineer.
Quote:
Originally Posted by nxwrxfx View Post
^^ okay for this... if i cant get it by hand with a wrench....
Would a small propane bottle blowtorch produce 700-900* F?

You are talking to an absolute greenhorn when it comes to metal work/welding/etc.

Don't worry about heating them up. Just bend them back. Like was said above, use a crescent wrench, or a large pair of channel locks.
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Old 11-11-2010, 09:36 AM   #11
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Looks like you got a good answer on the tabs. To answer your other questions, the rust is normal. Every APS FMIC kit I've seen is dripping rust from the support beam, if it's on an 04-05 where it uses the small tabs along the top for the bumper skin, those will rust all over the place too. Not a huge fan of the APS "quality" after working with and re-working several of their DR725 kits.
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Old 11-05-2010, 05:08 PM   #12
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Yes, it would.

I am being very conservative on temps. I do not want you to melt anything. If you heat up the tabs; let them air cool. When you can grab hold and not burn your fingers, that is the time to straighten things.

There is about a 4 hour window when the Al is easily bent. I've been known to come in on a Saturday with prototypes because that is when they came out of the oven and had promised parts on Monday.

Last edited by Web Foot STi; 11-05-2010 at 05:24 PM. Reason: N!
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Old 11-05-2010, 05:22 PM   #13
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Got ya, and that makes sense!
Thank you for the advice.

Yeah I really lucked out in a way because of where the tabs are bent.
I could literally get a flame on the tab area in question and I wouldn't be too worried about putting too much heat on the intercooler core itself. So here's hoping that either way, i should have this straightened out this weekend! *snare drum*
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Old 11-11-2010, 11:13 AM   #14
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Thanks for that piece of info downest!
Yeah I've been cleaning it up and so far it just looks like a bunch of light debris.
Honestly, for how rare these kits are becoming I shouldn't have freaked out so much.
But at the same time, with the economy being the way it is, you push to get the best bang for your buck!

Thanks for all the help though guys! I haven't had a chance to bend the tabs yet, but going to do so this weekend along with some other car tasks!
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