A hole is being made in the plastic intercooler end tank. A vacuum cleaner has been hooked up to the original intercooler outlet to suck out any particles caused by the creation of the new hole.

The end of the old intercooler outlet (with vacuum cleaner hooked up in photo above) has been sawed off. An aluminum tube has been carefully formed and flared at the end sticking into the intercooler to mechanically lock it into the hole. The plastic tubing from the old outlet has been slipped over the aluminum tube to "lock" it into place from the other side.

Most everything is looking good - all the fabrication work is done and the new tube has been epoxied into place. The old outlet stub will be capped off by a plumbing pressure cap. Except, there is one problem in the picture here. The marine-tex epoxy was a mistake, and like about 15 other adhesives I tested, didn't end up sticking very well to the end tank plastic. The connection eventually failed and resulted in a boost pressure leak. I ended up re-doing the connection with a special epoxy that I found at a radiator repair shop. They used it for repairing cracked radiator plastic end tanks. It sticks like crazy to my plastic intercooler end tank!