I am wondering what cheap ways have been used to intercool a '97 or older truck. I do not have 1500$ to drop on a kit, just married and starting a new career. So i am doing this on an extreme budget. Anyone use say a '99 and newer intercooler from a junk yard or similar?? if so what did you have to do to make it work? and how much money did you spend on it? I built custom rock buggies, truggies, jeeps, etc for 5 or so years. So i have the experience around automotive equipment, still have a shop full of tools. Just need a little push in the right direction.
Clay

 

Get a cooler off of a 6.0 PSD It cools alot better and has about the same mounts. Take a look at the H2e link in my sig for pics. There have been many variations on brackets so you can be the judge on that. I used thick rubber for the lower mounts.

Pipes will be different story. You can get a set of pipes from a '99-'03 7.3 PSD but you will have to modify one of them. If you go to a junkyard then get two passenger side pipes and you will have all the bends you need.

Y-pipe can be bought from the dealer now. It is from an early '99 7.3 psd. That is the only "stock" pipe that will work and they only made it for 1/2 a year. There are other designs but they are expensive.

 

Yep, any intercooler from a 7.3 or 6.0 can be made to work relatively cheap. 6.0's are generally easier to come by.

 

Is this the correct Y pipe?

 

Nope, that's a late 99-03. You need one from an early 99.

 

That is what it will look like but some of the connections will be smaller off of the early '99

 

or you can buy one from the master Gale banks himself... but i think it's like a hundred bucks...

 

Try $300 for the y-pipe or $500 for the whole pipe kit

 

yea, i said i wanted it on the cheap. like less then $500 for it all, having dp tuner do my pcm, and having beans do a 140v idm. it has 6637 filter, shimmed fpr, a banks turbo on it already, with a 3"ss downpipe and 4"ss the rest of the way out. just want a little more, sold my offroad rig to stop spending money...then i found another pit to sink it in.

 

I have $230 into my intercooler setup with a nice clean install. Its on it second revision with the swap of the 7.3 to 6.0 IC and will soon (I hope) be going into version 3 with install of a bigger turbo but none the less an IC can be added for $500 without issue as long as you can do some fab work and are a good parts hunter.

Here are some more links to help you on your path the PMS!
Tims I/C Page example (not my page its another Tim)
https://www.ford-trucks.com/forums/6...installed.html
Retrofit Intercooler pictures from friends & fun photos on webshots

Go to eBay and find the seller "Gobanks" he usually has good deals on take off 7.3 and 6.0 coolers and you can ask him about getting pipes with them.