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I am in the process of putting custom made aluminum tanks on a 6.0 cooler I have. We are making the tanks out of aluminum because the new engine has a QSSB on it that will push 45 #'s of boost and I was told that the plastic just wouldn't hold up.

My question is: How thick of material do I need to use on the inlet and outlet? We were thinking of using .090" at a bare minimum. The other thought was to use a 3/16" thick and machine down the lip to accept the boot. Has anyone done this yet?
 

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I've been told that the 7.3L plastic tanker intercooler "should" hold like 60 psi of boost??? Mine has held 40 psi so far without taking a dive yet. It could be bad info, so the aluminum tank will last longer. I would go with the 3/16 tube and machine the rest of the material off to make the ribs to hold on the boots.
 
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