I am about to take out my intercooler and expect to find the leak Sam has indicated develops in most around 100K. (I assume you suggest reinforcing the area that typically leaks, even if is not leaking, YET?)

However, I have the factory extended warranty until December. My question is Sam, would you put in a new IC, if available, for free, or would you repair the existing one, if you had the choice?

Could it be argued that the JB Weld repair should last longer than a new IC that has the same "weak point" as our existing OEM?

I have access to a great welder of aluminum. Might this be a better choice than JB Weld?

Thanks as always,

DOC

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2005 KJ CRD Ltd Detroit TrueTrac Bilsteins G2 GDE "HOT" ECU GDE TCM "Tow Tune" "euro" TC SEGR Weeks Elbow New HG at 130K ARPs Clean CAT aFe Filter Magnaflow Exhaust EHM Cumminos In-Tank Lift Pump Hayden Fan Clutch Nylon Fan VH Enabled with GDE lower shutoff point Recalibrated Temp Gauge Tekonsha Prodigy Sears P-1 ZDDP

One area that develops a leak is near the top hose neck, in the first couple of rows due to hose movement flexing the neck IMHO. The issue with welding on the IC is the plastic end pieces melting if the break is near there.

is there a better intercooler that is compatible or should you just be content with the JB Weld solution.

A great welder/Fab Shop could reuse the aluminum core and replace the plastic tanks with aluminum. Paint the tanks black and it would even look good.
The reason the Auto companies use plastic tanks is to save on cost and weight.
JB Weld is great stuff but not as strong as the plastic (might be ABS) or aluminum. If one were to locate the leak, clean up the area well with acetone as JB Weld recommends and apply a vacuum to draw the JB weld into the leak but not enough to collapse the tanks, the repair would be even better.

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2006 Pearl Green CRD
Magnaflow 2 1/2" Cat Back
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