Intercooler installation hardware
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Senior User
Joined: Apr 2004
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Intercooler installation hardware
Ok... I've been doing alot of research installing an I/C, and my concern is making brackets for the I/C itself and the hood support mod. I see most fab their own brackets, and have welders, presses, etc. All I have is a drill, sawzall, and a BFH. Would buying the Banks kit w/o the I/C ($700.00, w/ brackets, pipes, boots, clamps etc.) solve the welding/fab issue? This is about $200 more than piecing everything else together individually. All I need then is a used 7.3L I/C and install. Thoughts?
Hotshot
Joined: Jun 2007
Posts: 10,008
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From: Austin, TX
I'm not sure what the banks brackets look like, but I doubt they'll work.. I made my brackets when I installed a stock 7.3 IC and then I had to modify those brackets slightly to fit an aftermarket 7.3 IC. Where are you located? The best thing to do is find someone who can make the brackets to fit your IC and core support..
As far as the modification to the hood latch support goes, I just cut the part that runs down to the bottom of the core support off and leave it off. Some people weld in a cut down piece of angle iron, but I've been running without that lower part on the support for about 5 or 6 years now and never had a problem from it. I'm fixing to do another one that way too.
As far as the modification to the hood latch support goes, I just cut the part that runs down to the bottom of the core support off and leave it off. Some people weld in a cut down piece of angle iron, but I've been running without that lower part on the support for about 5 or 6 years now and never had a problem from it. I'm fixing to do another one that way too.
Fleet Mechanic
Joined: May 2005
Posts: 1,739
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From: Vale, NC
Your other option is to use the remaining $200 to buy a decent mig welder that will let you fab the brackets and then you'll have another too in your collection!!!! I don't think you'll need anything amazing in a welder - harbor freight or Northern usually sells a decent little mig welder with mask and all. just another route to consider
Hotshot
Joined: Jun 2007
Posts: 10,008
Likes: 7
From: Austin, TX
For the pipes I definitely prefer using a MIG with solid wire and gas... Much cleaner welds. I guess if you need it done on the cheap though, flux core will have to do.
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Hotshot
Joined: Jun 2007
Posts: 10,008
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From: Austin, TX
That will work, but a good TIG will make a way nicer weld on aluminum than a spool gun if you know what you're doing. It's tough figuring out how to set up the TIG for aluminum when you're new to it though. LOL Don't put a sharp tip on the tungsten, IIRC we used tri mix gas, reverse polarity, and it really helps to have a TIG that you can adjust heat on the fly. We originally tried it with a TIG that piggybacked off another machine and it kinda sucked for aluminum.
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Senior User
Joined: Apr 2004
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Yeah I like the idea of more tools in the garage.... a mig welder huh. So now on top of convincing my better half I need Stage 1's, and an intercooler, now I gotta explain how badly I need the welder as well. 
Post Fiend
Joined: Dec 2009
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From: Livoina,La