Compressor Intercooler (and Aftercooler)

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Very humid here in sunny Florida and it doesn't take much run time on an air compressor till it starts spitting water from the outlet, so I fitted an intercooler between my pump and tank. The frame is just some 2x2x1/8 angle. The intercooler has 1" inlet and outlet. Somehow I galled the (aluminum) threads on the inlet, so I had to weld in a 1/2" bung in order to repair it. The second item is another cooler I built from an old compressor tank and a car AC condenser coil. I'm not sure if it will need a fan or not. Attached ImagesMiller Thunderbolt AC/DC (Sold)Miller Dialarc 250HFMiller MM251Miller MM200 (Sold)Miller MM130Miller Spot WelderVictor O/A rigMiller Spoolmatic 1 (Sold)
Reply:Another pic of the tank mounted cooler. Attached ImagesMiller Thunderbolt AC/DC (Sold)Miller Dialarc 250HFMiller MM251Miller MM200 (Sold)Miller MM130Miller Spot WelderVictor O/A rigMiller Spoolmatic 1 (Sold)
Reply:Future plan includes an automatic drain valve on the water separator that will dump the bowl when the compressor ends it's cycle.Miller Thunderbolt AC/DC (Sold)Miller Dialarc 250HFMiller MM251Miller MM200 (Sold)Miller MM130Miller Spot WelderVictor O/A rigMiller Spoolmatic 1 (Sold)
Reply:whats the temperature difference across the first heat exchanger when it's all up to full operating temp?Welding/Fab Pics: www.UtahWeld.com
Reply:I don't have any hard numbers on temperature differential yet, but the tube running from the pump to the cooler is way too hot to touch, but the tube from the cooler to the tank stays cool after 5 compressor cycles. It has been rather cool here (for central Florida). The air temp was about 65. I emptied about 2 tablespoons of water from the separator after the  5 cycles.Miller Thunderbolt AC/DC (Sold)Miller Dialarc 250HFMiller MM251Miller MM200 (Sold)Miller MM130Miller Spot WelderVictor O/A rigMiller Spoolmatic 1 (Sold)
Reply:I expect it will work fine. I've seen alum finned copper heating pipe used as a cooler in the past..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:looks good, is the larger compressor left outside in the weather?Of all the things I lost I miss my mind the most...I know just enough about everything to be dangerous......You cant cure stupid..only kill it...
Reply:Originally Posted by roadkillbobblooks good, is the larger compressor left outside in the weather?
Reply:being outside is not helping with all the moisture in the air, inside would make a big difference and cut down on water in the system, can you pipe the intake into your shop?Of all the things I lost I miss my mind the most...I know just enough about everything to be dangerous......You cant cure stupid..only kill it...
Reply:This is a brilliant (to me) solution! I assume you used soft copper Type-L tubing? Flared the lines? For newbies like me, these details are important for me to emulate. Where did you find the intercooler? Was it a boneyard deal? Sorry so many questions, but the fine details would be of use to someone who wants to build what you've done here. Great job by the way.HTP Invertig 221Hypertherm Powermax30 XPPlus other stuff
Reply:Looks like a good and simple solution for that problem. I might have shaped a one or two turn coil on the copper tubing to give it more tolerance for movement and vibration, but you'll obviously notice if you get problems with it cracking over time.I would expect a car AC condenser to work well for this job too, for a very low price if bought at the right salvage yard.
Reply:Originally Posted by roadkillbobbbeing outside is not helping with all the moisture in the air, inside would make a big difference and cut down on water in the system, can you pipe the intake into your shop?
Reply:Originally Posted by SuperTroyeThis is a brilliant (to me) solution! I assume you used soft copper Type-L tubing? Flared the lines? For newbies like me, these details are important for me to emulate. Where did you find the intercooler? Was it a boneyard deal? Sorry so many questions, but the fine details would be of use to someone who wants to build what you've done here. Great job by the way.
Reply:Looks good man. How's it working for ya?
Reply:technically they're both aftercoolers since the heat exchanger isnt between pumping stages.I don't understand what's happening with the huge heat exchanger on the separate tank that's connected by a long hose... wouldn't the long hose give air a chance to cool down, not that it's going to even be warm anyway with the first heat exchanger right after the pump..?Welding/Fab Pics: www.UtahWeld.com
Reply:Originally Posted by Murphy's lawLooks good man. How's it working for ya?
Reply:Originally Posted by MikeGyvertechnically they're both aftercoolers since the heat exchanger isnt between pumping stages.I don't understand what's happening with the huge heat exchanger on the separate tank that's connected by a long hose... wouldn't the long hose give air a chance to cool down, not that it's going to even be warm anyway with the first heat exchanger right after the pump..?