Repairing Serck InterCooler

Repairing Serck Intercooler

Click on image to enlarge.

Photo no.1 shows a Serck Intercooler (air charge cooler), where the bronze end cover has been removed. On photo no.2 furthermore the tube stack has been disassembled. Unfortunately this intercooler has been in the hands of bunglers, for one thing the tube stack is oriented in a wrong way, for another they have not been careful when reassembling the unit.

When reassembling the intercooler, one has to be aware of the notch in the tube stack (the arrow on picture No.1), as it has to be placed outside the draw off tap on the end cover. This will partly ensure that the raw water can be drawn off, partly that the tube stack is placed correctly inside the aluminium casing and that the charge air is not led beside the cooling unit (tube stack).

And now the most important: Use new and intact O-seals when reassembling, and be careful that they do not get trapped! If the O-seal (inward ø115mm x 4) for one reason or another is not tight, salt water gets in touch with the aluminium casing and following a decomposition is started, which clearly is seen on the above photos, where large parts is corroded away, and has led to leak in to the charge air and in the worst case can lead salt water into the cylinders.

Perkins are not longer able to supply spare parts for the Serck intercooler. If you have lots of money and time to wait a new intercooler can be produced specially for the amount of 18000.-DKK + 25% VAT each. (app.. 1650 £+ 25% VAT). Delivery time 16-18 weeks (03.2004).

Here is two solutions to the problem:

1. This is what was done with the pictured unit. After disassembling the intercooler, unscrew the three bolts. With a rough file the worst corrosion is rasped of, whereupon the affected surface is sandblasted so the following rebuild with special paste will get a good grip (picture no.3).

The corroded parts is rebuilt by a special two-component paste "Wencon cream" (www.Wencon.dk), which amongst other things is used when repairing aero planes. When the paste is hardened, grind of, if necessary apply more paste, and again grind of. After this the casing is ready for reassembling (picture no.4).

2. The second solution is based on reestablishing the surface by putting on a stainless steel ring. The ring can be produced by companies which has laser cutting equipment, at a cost by making 2 pieces of 15 - 35£ each.

The affected surface is thoroughly cleaned, after which the surface is smeared with sealant e.g. silicone, and the ring is placed upon. See that the sealant doesn't flow into the casing. Then mount the tube stack, O-seal and end cover and tighten the bolts. One has to be aware of the fact, that the total length of the casing by this operation is extended by the thickness of the stainless steel ring, and if necessary this has to be compensated by milling off the casing.

2004