Disco 2 cracked intercooler.

whilst procrastinating over swapping my leaky rad for the nearly new one on my old D2, i was planning on swapping the intercoolers as my old one is an uprated aluminium one. however i noticed this-


its cracked right across the weld. i bought it 2nd hand ages ago and i dont know if it was like it when i bought it or if it happened after, or even how it happened - thats one of the stronger bits! either way, can it be repaired? would plumbing solder work?

Could be worth a go, but I've usually found with cracking like that it will run further like cracks in glass.

raywin said:

Could be worth a go, but I've usually found with cracking like that it will run further like cracks in glass.

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i reckon its cracked all the way round, judging by the 'step' in the weld. would solder 'take' on ali though? if it did, i could then possibly rivet an angled piece of ali over the corner, as it would still be a weak point.

Bobdog said:

i reckon its cracked all the way round, judging by the 'step' in the weld. would solder 'take' on ali though? if it did, i could then possibly rivet an angled piece of ali over the corner, as it would still be a weak point.

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no Solder wont work - it needs to be Aluminium brazed, which is a specialist job.

I'd say that you'll be hard pushed to get solder to stick to aluminium and even if you do it will always be a weak spot. IMHO, you'd be just as well off trying some epoxy "chemical metal".

yu could try this......

http://www.ebay.co.uk/itm/371161954555?ssPageName=STRK:MESINDXX:IT&_trksid=p3984.m1436.l2649

The Mad Hat Man said:

yu could try this......

http://www.ebay.co.uk/itm/371161954555?ssPageName=STRK:MESINDXX:IT&_trksid=p3984.m1436.l2649

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probably wont buy that one- £32 for 5 rods, a wire brush and a dvd!!
i've got a wire brush, screwfix do rods for about £2.99 for 6 and youtube is free!

Bobdog said:

probably wont buy that one- £32 for 5 rods, a wire brush and a dvd!!
i've got a wire brush, screwfix do rods for about £2.99 for 6 and youtube is free!

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You probably thunk about it already, but just in case, you might want to consider drilling a small hole at each end of the crack to stop it propagating.

Cheers

neilly said:

You probably thunk about it already, but just in case, you might want to consider drilling a small hole at each end of the crack to stop it propagating.

Cheers

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i think it already has. i believe its a flat square tube welded to the side. if there is no opening on the side 'tube' then i could just rivet an angle piece on to strengthen it, as there would be no air loss. if that makes sense