Definition of weld mapping: The planning of the order or pattern in which a part is welded to optimize aesthetics and reliability. Especially important on pressurized parts and parts made from materials that are known for cracking. (Aluminum, Inconel, stainless to steel welds, ect.) Notice the corners both on the inside and outside of these intercoolers. Every stop is covered by the start of the next weld. Many call this “wrapping corners” but that is just a part of weld mapping. When you get into more complex parts with more welds and more intersections it requires a plan of execution to ensure that all stops will be covered. Especially on aluminum where fish eyes are nearly impossible to eliminate completely this is very important. Even more so on a part like an intercooler that must hold pressure. On the outside of this part there is one stop visible on each end tank and that is from the final weld that didn’t have a weld after it to cover the stop, all other stops are covered with a start or a weld that runs over it in a “T” configuration. This planning is harder than you think and takes time to get used to, it’s kind of like a puzzle but the order in which you put it together matters.

Viper header #1 is mocked up, this weekend I will get the other one on and then I just need an oil filter relocation kit and I can get this engine in position for building motor and transmission mounts. I will be making a video on that process so stay tuned on the youtube channel!

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