Pressure testing a intercooler

I just got a used AGP direct fit intercooler in the mail today. I want to pressure test it.

I have a boost leak tester for the stock turbo, but the coupler is not big enough for the outlet pipes. I take it I am going to need a reducer coupler.

I will need to cap one end and start pumping air into it through the other end correct? The top of it had a sticker that said "pressure test to 60psi"

Any info would be great. I want to test it before it goes on the car this spring. The previous owner said it had no leaks, but of course I don't trust anyone.

 

I would do what you have written there.....Sounds reasonable enough.

 

X-2 i would test it at what they tested it at.

 

Stupid question, how will you know a intercooler has leaks? Is it like a boost leak test and you will hear a "hiss" coming from somewhere?

 

yes if it has a leak it wont hold any pressure or very little preasure.
and will probally have a hiss.

 

Cool, thanks for the quuick responses!

 

spray some soapy water on the welds, or any areas of concern. if it bubles then you have a leak

 

What sizes do I need you guys? 2.25'' to 2.5'' reducer coupler?Or is it 2''-2.25''? Talking about the boost leak tester, I need to switch out the piping that is still on there.

Edit:
got it. ITs 2.25'' to 2.5''

 

Well I got the reducer in the mail, and I can't think for the life of me on what to use to cap the other end.. any ideas?

 

go to home depo or lowes and by a plummers cap, its a PCV pipe cap, found around the toilet section.
and pressure test it lower. like around 15 or so PSI

 

Thanks, will do.

Why 15 and not the recommended 60?

 

because that cap isnt for pressure testing and the rubbers somewhat plyable, if you put too much it'll pop like a balloon. as long as you get a good seal on the cap i'll work and you can do your test. some pressure is better then no pressure. and make sure you use soap and water like said above.

 

Just got to thinking. How will a PVC pipe on a aluminum pipe be air tight? How would a hose clamp secure it on there? Or basically, what would secure it on there to be leak free? Hopefully they aren't expensive. If it is I will just get my money back after I used it.

 

The cap he is talking about is made of rubber, not PVC.

 

re read below

the cap should cost around $10

 

Okay gotcha!

 

Well, went to Home Depot and they only had 2'' caps. I can see why you said it would blow up like a balloon. Since its all rubber! Talked to the guy and he said plumbing stuff is usually only even numbers. He recommended this plumbing supply place called "Reeves something something." lol Gonna yellow page it plumbing supplies.

 

because its a flexable rubber you could stretch it over the end cap all you have to do is streach it .5 in.

 

So it would of worked!? I know my 2.25'' coupler from my boost leak tester wouldn't fit. But its a different material. Its really that flexible.. damn..

 

Got the 2'' cap and it worked fine for pressure testing the intercooler. Went up to 15lbs and it blew the damn tester off! Went up to 15 again, and it held it solid. My intercooler wasn't losing any air. Stayed at 15. =)