Want to Drill the Intercooler For Drain Valves - Need your Comments

[irondoor19]

So we have the Intercooler out of the Car (and the core Support) and it has been
cleaned (but we are not happy with what we see inside after cleaning).
So we are ready to sacrifice it in order to test out the Following:

We have looked into Exactly Where it can be Drilled for two 1/4" Drain Valve's,
One on either End. This would have to be done in the Plastic Section Only at each end...
the initial Question: If we drill and tap this plastic, what are the chances that the
minimal amount of threads will hold under boost Pressure. (and or J/B Weld)

IF SO Then we will also drill a 2" hole in the Core Support on both sides,
to allow access to the Drain. "your initial comments are welcome"

[ZSHO]

Please save yourself from future potential headaches and DO NOT DRILL the Intercooler. Z

[MiWiAu]

Please save yourself from future potential headaches and DO NOT DRILL the Intercooler. Z

^ +1


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[jayskycj]

I think those who are in favor of not drilling it have never experienced these issues and how critical the surging and powerloss is.  The F-150 guys go into extensive detail with results.  The knee jerk reaction is the sky is falling with this 1/16" hole.

Edit, post weep hole from an F-150 owner:

www.youtube.com/watch?v=QXP1KBXSny8#action=share

[ZSHO]

I think those who are in favor of not drilling it have never experienced these issues and how critical the surging and powerloss is.  The F-150 guys go into extensive detail with results.  The knee jerk reaction is the sky is falling with this 1/16" hole.

Edit, post weep hole from an F-150 owner:

www.youtube.com/watch?v=QXP1KBXSny8#action=share

This Forum does not support this so-called mod as it can have and ultimately cause severe implications long term and we need to move on. Z

[F150Eco]

I have seen this topic beaten to death. A large number of people with f150 boosts have drilled the hole and seen no problem from it, but have cured persistent problems. I don't like the idea of over speeding it over time, but without an intercooler that has provisions for a bov on the bottom (as the Full Race does for the f150), what else are we to do?

I've contemplated drilling the hole and plugging it with a screw. Open once in a while to clear it out.

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[irondoor19]

I think i am being Misunderstood here, The Question was:

We are Contemplating Putting in 2 Drains into the intecooler,

both of them with 360 Single Turn Valves, AND as now i have

a Used Intercooler to play with....Drilling, then Threading the Plastic,

Additionally Sealing in the Valve Etc, would the Setup withstand the Pressure

in the system...IS THIS POSSIBLE......

Also: after a long conversation with the Ford Dealer Mech...

the F150 Problem is specific the the F150, and not the same
problem for our platform (F150 intercooler is too Efficient)

[avidmotion]

The new GH intercooler has such a provision I believe on the drivers side, just saying......

[SHOdded]

All depends on how sturdy the plastic is, material and thickness of material.  It has to be pretty sturdy to hold boost pressure, so I think as long as drill the hole carefully, have the drain plug very precisely matched, and use a good sealing gasket rated for oil, fuel, water, acids, etc. it should work.  There is no undoing this, of course, and there is always the possibility of the plastic cracking.  Driver side is preferred because that is where the most crud accumulates.

[nickstewartroc]

The real question is... since this OP was from 2 years ago, did they actually do it?

[SHOdded]

Nope, did not.

[SM105K]

Holy dead thread Batman!

[ZSHO]

I would proceed with caution as the slightest Pin hole can ultimately cause a boost leak unless installed properly using a 1/4" NPT Aluminum or steel Bung IMO! Z

[irondoor19]

The new GH intercooler has such a provision I believe on the drivers side, just saying......

So as this has re-surfaced, "Why i don't know"
the Gearhead intercooler does have a Drill and tap plug on the Bottom,
and Prior to total assembly and completion of the Engine, trans ETC., IT
might be a good time to ADD a 360 Petcock drain in leu of that plug....?