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I've got the 03 supercrew with a 38 x 18" radiator. I need a radiator that is about 16" tall. The 4bt runs pretty cool so it won't matter that i lose surface area. The deal is that it needs to be a radiator that has no cap with a resevior on the side. I'm needing it shorter to get the intercooler piping over the top of it.
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Have one made witha thicker core.
I would not reduce the cooling capacity.
Good luck.
The one that came with the Frito-lay van is brass and it could be shortened a couple of inches with no trouble. I have seen some websites on custom aluminum radiators for 120 plus shipping. One of them is a double pass which means the inlet and outlet can be on the same side. Anyway i'm still exploring it all. How much cooling difference do you think the addition of an intercooler makes?
I don't have an exact answer only to the point out that the intercooler adds some heat to the radiator behind it same as an A/C condenser does unless the heat exchanger is mounted some other location.
My point is why reduce the radiator capacity and take a chance on an overheating issue.
The heat any motor produces is directly a function of how much air and fuel is passed/forced through the motor and converted to make the power. It's called BTUs.
It you Turbo Charge any motor you generate more heat and exhaust gas flow. This is what turns the turbos.
There is a general rule of thirds. 1/3 of the total energy produced is lost to the cooling system, 1/3 to exhaust output and 1/3 converted to turn the crank. Total is 100%.
You lose about 2/3 of the total energy generated just to move the weight of the vehichle at speed with the remaining third.
I will admit that a diesel is more efficient than a gas motor just due to the higher compression ratio, recovering more of the expended energy..
That can be done in a gas motor but fuel octane become an issue as well as ignition timeing for all but a specific use such as some form of racing.
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