Intercooler and learning to weld aluminum

I would be lying if I said I’ve enjoyed building this intercooler. It seems to have fought me the entire time.

For never having welded aluminum – I’m happy with the look of the weld. Unfortunately when I went to pressure test it I have a number of leaks from the core. Like a bad game of “whack a mole” I seem to fix them and then find new ones..

Sadly at this point I’m going to cut off the end tanks and try again. It’s unfortunate but I am not sure what other choices I have. Most shops are not willing to try welding the current project and I’m not ready to throw a $400 core away. Stay tuned for updates