Ok this isnt my car lol. I know a kid who has a new Cobalt SS/TC and the intercooler has a hole in it. The dealer says its not warranty and wants almost 700 for a new one. He definitely doesnt have the money for one, so just thought I'd ask if anyone knew of a way to seal it up.

if there was a way it would either be some form of soldering or really low temp aluminum welding. odds are probably not. but how is it not warranty?

bc pressurize air goes thru it, and the ss/tc does at time oput out close to 20psi, it would be best to repace it, but for 700 go and get a aftermarket intercooler kit, they run about the same cost, look into synapses, hahn, i would personally do synapses, but to each their own, and welding it may work, but require a perfect weld bc one again, its pressurized air, it will escape from any where i can get out from...must be a peak free weld, which is somethings difficult to do in a intercooler

Guess he bottomed out the car and broke off the mounting tab which in turn cracked it

Yeah he'll be doing the synapse kit eventually. I actually just found out that the crack is is in the plastic part of the cooler(YAY factory crap!). I have a plastic welder kit, so i'm gonna seal it up as best as i can with that. He'll just need to not beat on it to much till he can get it replaced.

if its the plastic part u can try some quick steel

I know you already found the problem but for those who might look back at this.
Intercoolers and radiators are welded all the time. Find a good TIG welder in your area and have them do it if you can't TIG yourself. No big deal, and 20spi isn't at all a problem for a good weld/welder.


"Never argue with an idiot. They'll drag you down to their level, then beat you with experience!" -Anonymous