Intercooler

So I actually did this about a year ago, but here are a few pics. TIG welding thin aluminum is not easy, and I was fortunate to have the assistance of a friend who's a great welder when I got stuck.

Mocking up the end tanks, all cut and bent by hand out of aluminum sheet metal:

 

All welded up:

 

Mounts welded in place (though you can't see them)

 

Bolted up on the four mounts:

 

Not much room to spare here...

 

Piping all welded up and painted:

 

Everything Installed:

 

Since this picture was taken, I've removed material from the back of the grill and gotten it to fit back on. The winch soleniod needs to be remounted inside the engine bay.