Intercooler core install?

**Pure2sin** · 06-21-2012

After cutting my own gaskets out of a material PRJ suggested, I still had leaks. I then spread RTV all over the gaskets on both sides and installed them. This made for a tight seal but was way too hard to take off and broke my core upon removal.

Instead of buying some more of the expensive material again I went to O'Reillys and bought some material I found there for $5 a roll. I then cut some gaskets out of that:

It's 1/16 of a inch and made of rubber and fiber (Fel-Pro #3157). It should work out well for this application and it way more flexible and should seal better than Garlock gaskets.

The question I have now is not to use RTV or not, but how much to use?

I found these pictures on what ZZP says for the install of their cores with Garlocks. I am wondering if anyone has put the RTV on like this with success.

**Explicit_Spade** · 06-21-2012

Yes, that is the proper way to RTV.

I'm kind of confused about how you had a hard time getting the RTV to separate...

**Pure2sin** · 06-21-2012

I spread it all over the gaskets on both sides. I didn't only do a small bead like shown in the picture above.

**BillBoost37** · 06-21-2012

I use that same Fel Pro stuff and Permatex 26B like you see in the pictures you posted. it can still be tough to seperate, but it will seperate.

**matt5112** · 06-21-2012

I found carb cleaner broke most of the bonds.

**Explicit_Spade** · 06-21-2012

Carb cleaner or brake cleaner are great to break RTV. If those don't do the trick, use a poking tool to break the seal then run the smallest screwdriver you can find across until you can break it by hand. Don't apply pressure at an angle with a tool, phenolic and aluminum don't like that.

Along with the thin lines above, you can run a ring around the outside for added insurance against leaks. Thats how I did it (without a gasket) and never ran into a problem after that.

**Rico** · 06-21-2012

A thin narrow putty knife works good also.
Get it started and use the palm of your hand to tap it in.
It usually destroys the gasket though.

Don't ever pry with a screw driver; you'll ding, dent and bend the hell out of the parts.

**BillBoost37** · 06-21-2012

You guys don't quite understand..lol.

I use a prybar to pop the core loose.

**Pure2sin** · 06-21-2012

Originally Posted by BillBoost37

You guys don't quite understand..lol.

I use a prybar to pop the core loose.

That's what I had to use when I was taking the core off this last time and I broke it. I think I went a little overboard on the RTV lol

I will be doing the bead and instead of spreading it all over like I am making a peanut butter and jelly.

**Ricky21** · 06-21-2012

This is the same thing im doing here are the gaskets I cut. I feel like I am missing some holes, but these were the only ones that were on the core. But I think the lim has a few different ones that dont line up?

**Pure2sin** · 06-21-2012

Mine is all sealed up. I am going to give it 24 hours before I start it up. Cross your fingers.

New axles tomorrow with the modded sway bar end links and I should be good to go.

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