With our first prototype intercooler and shroud assembly complete, it was time to test fit and make necessary changes or adjustments.
Prototype Cummins Intercooler Test Fit
Using the factory mounting brackets, we bolted our components into place.
The front shroud fits nice and snug against the front bumper and grille. The core is definitely in an ideal position for optimal airflow.
Our team then worked to install the rear intercooler shroud, which mates with the cooling fan plastic shroud.
It was here that we ran into a slight fitment issue. The altered core size we designed pushes the shroud farther back toward the engine. Unfortunately, this means our shroud contacted the steering gearbox.
A bit of work with the cutoff wheel, and we had space to install the prototype.
We can’t just leave an open gap in our shroud. Dimensions were captured from the cutout, and we bent a piece of aluminum to seal the shroud.
This was then fully welded.
Coming Up – 3D Models
We’re getting closer to finishing our design. For the next few weeks our team will be obtaining dimensions from our 3D-printed prototype and shroud and will then create a finalized model in Solidworks. Check back next time for an awesome update!
Thanks for reading!