HPF Intercooler

vasillalov · 09-15-2011, 09:21 AM

I received my HPF intercooler last night directly from HPF and I have a few questions and concerns about the unit I was sent:

There seems to be a good amount of welding flux that is still stuck inside the intercooler where the core is welded to one of the end tanks:

Also, that flux is present on the outside of the intercooler at the corners where the core is welded to the same end tank:

My questions:

* Is leaving this much flux still stuck on the intercooler a common practice?
* Should I be worried about any boost leaks? Does this look like they tried to cover up a crappy weld job?
* What is the best way to clean this flux out?

Thanks for your time in advance!

boom · 09-15-2011, 09:30 AM

That looks like shit. Quality control FTL. I don't think the flux will hurt anything but make sure there is no debris inside. Blow it out with compressed air and try to do a leak test.

Alan l. · 09-15-2011, 09:35 AM

That last pic has me concerned. I would email HPF about this. I'm positive they will take care of it asap if you went through them directly.

Beemw335 · 09-15-2011, 09:35 AM

I would say, return it and ask for another one.
Im surprised with hpf, single turbo my ass thats never gonna happen.

posite · 09-15-2011, 09:55 AM

I bought mine second hand and didnt see anything of the nature. Never messed with welding flux before but perhaps cleaning it out with gasoline assuming HPF doesn't help with replacement..

tpipta · 09-15-2011, 09:57 AM

Busch league. They should definitely pony up and give you a replacement. If the next is the same quality, I would look elsewhere for something of better quality.

Best,
Tony

TurboBullett@Ambient Thermal Management · 09-15-2011, 09:58 AM

looks like a sealing epoxy used after manufacturing due to a leak during final leak testing!

vasillalov · 09-15-2011, 10:02 AM

Quote:

Originally Posted by TTurboBullett

looks like a sealing epoxy used after manufacturing due to a leak during final leak testing!

I am not so sure about that. I've played with several different kinds of epoxy and this does not exhibit the same properties. I took a long screw driver and I poked at the material inside the intercooler stuck on to the end tank. It is VERY brittle, thin and it looks like residue. All of the epoxies that I've worked with are very hard, non brittle and very durable when hardened.

Beemw335 · 09-15-2011, 10:03 AM

Quote:

Originally Posted by TTurboBullett

looks like a sealing epoxy used after manufacturing due to a leak during final leak testing!

+1
i forsee the leaks this guy is going to have.

TurboBullett@Ambient Thermal Management · 09-15-2011, 10:34 AM

Quote:

Originally Posted by vasillalov

I am not so sure about that. I've played with several different kinds of epoxy and this does not exhibit the same properties. I took a long screw driver and I poked at the material inside the intercooler stuck on to the end tank. It is VERY brittle, thin and it looks like residue. All of the epoxies that I've worked with are very hard, non brittle and very durable when hardened.

very weird it may very well be a cleaning agent to remove the rouge.

Clap135 · 09-15-2011, 10:37 AM

That looks like good ole china quality with a usa price tag to me

vasillalov · 09-15-2011, 10:38 AM

Quote:

Originally Posted by TTurboBullett

very weird it may very well be a cleaning agent to remove the rouge.

How do I go about cleaning the "cleaning agent"? Is it water soluble or do I need special chemicals to remove it?

I sent an email to HPF with pictures and a description of the problem. Hopefully, they'll either replace it or tell me how to get rid of that stuff...

vasillalov · 09-15-2011, 10:39 AM

Quote:

Originally Posted by Clap135

That looks like good ole china quality with a usa price tag to me

All of them are like that. Helix intercoolers are made in China too. Nothing new...

Syndicategt · 09-15-2011, 10:44 AM

Pour some acetone in there (like you would when cleaning out blowby), should clean it right up.

dzenno · 09-15-2011, 10:47 AM

Send the pics over to HPF and get their opinion on it

vasillalov · 09-15-2011, 10:49 AM

Quote:

Originally Posted by dzenno

Send the pics over to HPF and get their opinion on it

Done!

I was just trying to get as much input as possible and also as a precaution in case they try to feed me BS. I highly doubt that'll be the case. Most probably this is some residue left over during the welding of the end tanks. I'll wait for HPF's response and I'll take it from there.

alr335xi · 09-15-2011, 10:51 AM

Looks like shit, should of went with the ETS 7"! Return it and call Mike @ ETS. There work is top notch. They would of never sent anything out like that.

BlueLion · 09-15-2011, 11:02 AM

this is making me nervous

chinesechicken · 09-15-2011, 11:04 AM

just return the it and send HPF the same pictures you posted im sure they will warrant their products

cwn23 · 09-15-2011, 11:05 AM

Not normal...Mine came in pristine condition...I would send it back especially paying top dollar for it

vasillalov · 09-15-2011, 11:07 AM

Quote:

Originally Posted by BlueLion

this is making me nervous

... and your avatar makes me horny!

Andrew@LutzPerformance · 09-15-2011, 11:09 AM

Vasil,

Definitely not normal, and very abnormal for something like that to make it out of QC out of HPF.

They stand behind their product 100% and you will be given a fresh new one that is thoroughly gone through and in perfect shape.

Email me if you need anything at all!

09-15-2011, 09:21 AM	#1
vasillalov Mad Linux Guru On The Loose 1121 Rep 5,396 Posts Drives: 2008 335i Sedan, 2023 M3 Join Date: Aug 2009 Location: Chicago, IL iTrader: (5) Garage List 2023 BMW M3 [0.00] 2008 335i E90 [8.00]	HPF Intercooler - Is This Normal? I received my HPF intercooler last night directly from HPF and I have a few questions and concerns about the unit I was sent: There seems to be a good amount of welding flux that is still stuck inside the intercooler where the core is welded to one of the end tanks: Also, that flux is present on the outside of the intercooler at the corners where the core is welded to the same end tank: My questions: * Is leaving this much flux still stuck on the intercooler a common practice? * Should I be worried about any boost leaks? Does this look like they tried to cover up a crappy weld job? * What is the best way to clean this flux out? Thanks for your time in advance! __________________ 6MT \| COBB \| AR \| AE \| Forge DV \| HPF \| P3 Gauge \| Hybrid Intake \| O.S.Giken TCD \| All M3 bits \| TCKLine \| StopTech \| UUC \| ER \| SPEC
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09-15-2011, 09:30 AM	#2
boom My X5d tows my spec miata to the track. 74 Rep 1,254 Posts Drives: 2010 X5 35d Join Date: Sep 2009 Location: USA iTrader: (0)	That looks like shit. Quality control FTL. I don't think the flux will hurt anything but make sure there is no debris inside. Blow it out with compressed air and try to do a leak test.
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09-15-2011, 09:35 AM	#3
Alan l. Major General 5453 Rep 8,815 Posts Drives: 2020 F95 X5M Competition Join Date: Jun 2009 Location: United States iTrader: (9)	That last pic has me concerned. I would email HPF about this. I'm positive they will take care of it asap if you went through them directly. __________________
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09-15-2011, 09:35 AM	#4
Beemw335 Colonel 62 Rep 2,013 Posts Drives: 335i Join Date: Mar 2011 Location: My car is my home iTrader: (2)	I would say, return it and ask for another one. Im surprised with hpf, single turbo my ass thats never gonna happen.
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09-15-2011, 09:55 AM	#5
posite Second Lieutenant 12 Rep 232 Posts Drives: 07 335i Join Date: Jan 2011 Location: TX iTrader: (5)	I bought mine second hand and didnt see anything of the nature. Never messed with welding flux before but perhaps cleaning it out with gasoline assuming HPF doesn't help with replacement.. __________________ 07 335i 12 335i 09 335i
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09-15-2011, 09:57 AM	#6
tpipta First Lieutenant 24 Rep 318 Posts Drives: F15 X5 Join Date: Apr 2008 Location: Annapolis, MD iTrader: (0)	Busch league. They should definitely pony up and give you a replacement. If the next is the same quality, I would look elsewhere for something of better quality. Best, Tony __________________ 2008 AW 335i (Lemon), 2009 AW 335i (Round 2 w/ Basic Mods), 2011 BSM 335i LCI MSport (Sucked), 2010 PW MINI Cooper S Hatchback, 2014 AW M235i, 2017 X5
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09-15-2011, 09:58 AM	#7
TurboBullett@Ambient Thermal Management Major 80 Rep 1,283 Posts Drives: 2012 Abarth 500 Join Date: Jun 2007 Location: NJ iTrader: (3)	looks like a sealing epoxy used after manufacturing due to a leak during final leak testing!
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09-15-2011, 10:37 AM	#11
Clap135 Brigadier General 102 Rep 3,460 Posts Drives: 2009 N54 Join Date: Jul 2009 Location: Sticky's Mom House iTrader: (1)	That looks like good ole china quality with a usa price tag to me
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09-15-2011, 10:44 AM	#14
Syndicategt Brigadier General 153 Rep 3,730 Posts Drives: 335i Join Date: Sep 2009 Location: Nor Cal iTrader: (11)	Pour some acetone in there (like you would when cleaning out blowby), should clean it right up. __________________ 2008 BMW 335i e90 - Sold - Rob Beck Turbos / PROcede V5 / Aquamist HFS-4 / AR Downpipes / AE Exhaust / ER Comp FMIC / ER CP / TiAL BOV / Custom Intake / RPI Scoops / Quaife LSD / Swift-Koni Coilovers / DSS HS / Morr VS8.2 Sig Black / Michelin PSS / P3 Boost Guage / M3 body / M3 steering wheel / Adam's Rotors / Hawk HPS / SS lines /
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09-15-2011, 10:47 AM	#15
dzenno Banned 273 Rep 5,876 Posts Drives: Join Date: Feb 2006 iTrader: (1)	Send the pics over to HPF and get their opinion on it
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09-15-2011, 10:51 AM	#17
alr335xi McB Autosport 10 Rep 125 Posts Drives: E90 335xi Fully Built Join Date: Apr 2011 Location: Murrysville,PA iTrader: (0)	Looks like shit, should of went with the ETS 7"! Return it and call Mike @ ETS. There work is top notch. They would of never sent anything out like that.
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09-15-2011, 11:02 AM	#18
BlueLion she likes the flavor...... 85 Rep 1,622 Posts Drives: A51-E92 Join Date: Nov 2006 Location: Bradenton - FL iTrader: (4) Garage List 2022 X3MC [0.00]	this is making me nervous __________________ E92 Montego Blue silfa718 ..::STETT CAI\|ADVAN RS\|WAGNER FMIC\|MS DP\|VANGUARD\|PROCEDE\|FORGE DV\|BMS OCC\|KWV2\|MICHELIN PSS\|OOS::..
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09-15-2011, 11:04 AM	#19
chinesechicken S3X DR1VE 1 Rep 52 Posts Drives: 2009 E92 335i Coupe Join Date: Aug 2011 Location: NYC iTrader: (0)	just return the it and send HPF the same pictures you posted im sure they will warrant their products
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09-15-2011, 11:05 AM	#20
cwn23 Major 23 Rep 1,142 Posts Drives: E92 Join Date: May 2007 Location: USA iTrader: (0)	Not normal...Mine came in pristine condition...I would send it back especially paying top dollar for it
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09-15-2011, 11:09 AM	#22
Andrew@LutzPerformance 60 Rep 970 Posts Drives: 1995 M3 GT35R Join Date: Dec 2008 Location: 6333 N Dale Mabry Hwy Tampa, FL iTrader: (0)	Vasil, Definitely not normal, and very abnormal for something like that to make it out of QC out of HPF. They stand behind their product 100% and you will be given a fresh new one that is thoroughly gone through and in perfect shape. Email me if you need anything at all!
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